Predictive Maintenance Software Development

Ensure more accurate, prompt, and cost-effective equipment maintenance with an intelligent predictive maintenance solution by Emerline.

10+

Years of experience working with predictive maintenance software

Over the years, we've accumulated many real cases and established a large list of clients worldwide, encompassing North America, Europe, the Middle East, and other regions.

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Our Clients

Your Business Benefits With Emerline’s Predictive Maintenance Software

Reduce downtime

With IoT sensors, you can track equipment conditions in real-time. You will always have proactive insights to decide which assets require maintenance to prevent their breakdowns and downtime.

Cut maintenance costs

Address tech issues before they escalate into costly repairs. With IoT-powered tracking, schedule maintenance procedures more efficiently to reduce maintenance, operational, and labor costs.

Extend equipment lifespan

Real-time equipment monitoring enables you to conduct preventive maintenance proactively and keep assets in operational conditions longer, thus extending their lifespan and preventiving repairs.

Boost operational efficiency

With reduced downtime and production interruptions, you can now delegate more strategic tasks to your maintenance personnel rather than having them respond to tech issues once they happen.

Make data-driven decisions

Gain maintenance insights in real-time and adjust your maintenance strategies accordingly. You can also use historical data to identify and exclude bottlenecks in the current maintenance processes.

Provide a safer working environment

Perform predictive maintenance to prevent equipment failures and minimize workplace incidents. Maintaining the working environment’s safety ensures continuous compliance with safety regulations.

Predictive Maintenance Solutions We Delivered

Smart equipment maintenance solution for steel and mining company

Our client, a large steel and mining company, needed a modern software solution that could enable them to predict equipment failures, schedule maintenance procedures, and reduce associated costs. At some point, their legacy software could no longer accommodate the growing enterprise’s scale to complete this task. We provided an entirely new solution that ensured the proactive management of failure risks by calculating the mission-critical performance metrics in real-time.

FUCHS: an advanced platform for maintenance inspections

We provided a comprehensive enterprise solution for a well-recognized industrial manufacturer to cover its main operational tasks, including continuous equipment maintenance monitoring. We empowered them with advanced, real-time analytics capabilities, which allowed them to collect info from plants, sensors, tags, and other devices. With these capabilities, the client could continuously evaluate the conditions of mission-critical equipment and spot the signs of potential failures in advance to prevent downtime.

Oomnitza: all-in-one enterprise asset management solution

Large enterprises typically need flexible software to accommodate their growing needs without interrupting the core operation. One of our clients approached us with the task of replacing their current software, which could not scale to meet their unique requirements: real-time management of multiple assets at once. We built a real-time monitoring solution from scratch, allowing them to track assets end-to-end, including their production, condition tracking, performance, and other aspects, and plan maintenance procedures before failures happen.

Are you planning to enhance your enterprise workflows with predictive maintenance software? Emerline is here to answer your concerns.

Frank Lozinski

Account Manager at Emerline

Emerline’s Predictive Maintenance Software Development Services

As recognized IT experts, we deliver end-to-end services for clients in the enterprise sector struggling to reduce maintenance costs and downtime to increase operational efficiency. Request our professional software development services today and get assistance through the project’s lifecycle, or contact us to get support on a particular stage, be it discovery, development, consulting, data operations, or others.

Business case discovery

Get predictive maintenance software that meets your unique business needs and fits your maintenance workflows. We thoroughly analyze your company’s use case through design-thinking sessions and offer a solution to your business challenges. Once we approve the application’s idea with you, we create a step-by-step delivery roadmap, considering potential challenges in the development process.

Software and technology consulting

Choose the right software solution for your equipment maintenance workflows with Emerline’s expert domain consultants. Based on your requirements, they will advise you on the proper functionality set and technology stack to implement.

Custom predictive maintenance software development

Ensure more accurate, productive, and cost-efficient equipment maintenance with bespoke software designed specifically for your enterprise. In addition to the delivery itself, we will ensure your smooth product onboarding by conducting hands-on sessions on how to use the software to complete your business tasks.

Data integration

Request dedicated data integration services from Emerline and take advantage of IoT connectivity by collecting real-time data about your equipment performance from the connected sensors. In addition to IoT, we can provide tools for aggregating your maintenance data from various sources, such as history logs, sensors, and ERPs, in one place and create APIs to ensure seamless data transfers between distributed systems and/or platforms.

Data management

We will ensure your data is ready for comprehensive and consistent analysis by cleaning and preprocessing raw data and implementing scalable and secure data storage solutions, such as data warehouses, data lakes, or cloud platforms.

Data migration

Seamlessly move historical data from the existing enterprise software to a newly built predictive maintenance solution to pick up where you left off in your equipment maintenance workflows, yet with more advanced capabilities. The Emerline team will support your migration strategy, including data governance, transfer, and testing through a time-efficient, fully manageable data migration process that we arrange with DataLark, our own data management solution.

Software customization & integrations

Add new features to enhance the capabilities of existing enterprise software, whether ERP or a more specific equipment maintenance solution. We analyze your business challenges, identify areas of improvement, and transform them into actionable feature ideas. We provide all the required customizations within the agreed-upon roadmap by developing new features from scratch and/or integrating third-party APIs.

AI/ML integration

Make informed maintenance decisions by increasing the accuracy of your maintenance management with custom AI and ML tools and existing products from the industry giants like Amazon, Google, Microsoft, and others. These give you more analytics insights by deriving them from real-time data, historical records, and existing patterns. Forecasting future trends allows you to adjust the maintenance process to increase operational efficiency.

Cloud migration

By migrating your equipment maintenance software to one of the high-performing cloud platforms, you can discover unlimited scalability opportunities for your data architecture and reduce database maintenance costs. We will offer the best cloud option that aligns with your budget and business needs and arrange the seamless migration process, with all data and dependencies preserved.

Support and maintenance

On request, we will support your application after the release with regular, comprehensive testing procedures to keep its performance stable, add-ons and customizations based on your current business needs, and our in-depth market analytics and training sessions to onboard new users on the application.

Our Industries of Focus

Through years of working with clients in different industries, we’ve been broadening and enforcing our expertise as a custom software developer, flexible enough to adjust our workflows and software solutions to your unique needs. Below, you can see the main domains where we excel.

Manufacturing
Energy
Transportation and logistics
Oil and gas
Healthcare
Automotive
Real estate
Telecommunications

Manufacturing

Prevent failures in production line equipment, such as printed circuit boards (PCBs) assembly machines, CNC machines, conveyor belts, and more, to reduce downtime and stay within production schedules.

Energy

Monitor the performance of power plants, grids, turbines, and solar panels in real-time to prevent downtime, optimize maintenance scheduling, and ensure consistent and optimal energy production.

Transportation and logistics

Reduce vehicle breakdowns by tracking the critical performance parameters (tire pressure, engine condition, etc.) in real-time. Leverage ML-based diagnostics and failure predictions for logistics safety.

Oil and gas

Timely predict leaks and corrosion in pipelines to prevent environmental threats, take advantage of real-time maintenance monitoring, and proactively control the performance of refinery equipment.

Healthcare

Track the performance of critical medical equipment (MRIs, CT scanners, ultrasound machines, ventilators, etc.) to ensure it always operates as intended. Proactively check if the equipment needs maintenance.

Automotive

Take advantage of telematics data to monitor production line equipment and vehicle conditions in real-time, prevent breakdowns, and streamline manufacturing procedures.

Real estate

Monitor your infrastructure’s operating conditions in real-time by proactively detecting maintenance needs in any of its constituting equipment, such as HVAC systems, lighting, doors, elevators, etc.

Telecommunications

Maintain stable, uninterrupted network performance by continuously monitoring cell towers, base transceiver stations, switches, routers, and other equipment to deliver quality communication services.

Do you have unique equipment maintenance challenges and are unsure how predictive maintenance software can help you?

How Predictive Maintenance Software Works

Predictive maintenance consists of three steps to efficiently predict equipment failures and schedule maintenance procedures accordingly.

1
Detecting threshold values
2
Data collection and analytics
3
Model training
4
Data presentation
5
Decision-making
Let’s Start!

Detecting threshold values

At this stage, the user identifies the enterprise-specific parameters and their limits based on which the system will be then detecting normal and abnormal equipment operation conditions. The defined threshold values are the benchmarks that will trigger alerts upon deviations from the normal operating conditions.

Data collection and analytics

Next, the system gathers data from various sources and analyzes it so you can make proactive maintenance decisions.

  • Aggregating data from distributed sources, such as sensors, historical records, ERPs, and others, into a centralized location.
  • Clean and preprocess data for better accuracy and consistency.
  • Using descriptive analytics to understand the equipment’s current state and performance trends from the historical data.
  • Performing diagnostic analysis to identify root causes of detected anomalies or operational deviations (if any).

Model training

At the model training stage, the solution develops and refines ML models based on all the available data to predict failures and potential outages.

  • Preparing a dataset.
  • Choosing the appropriate ML algorithms (e.g., regression, classification, time-series analysis) depending on the task.
  • Training the model using the prepared dataset.
  • Validating the trained model for accuracy and performance.
  • Refining the model’s features to ensure more accurate predictions.
  • Deploying the trained model to analyze real-time and historical data and predict equipment failures.

Data presentation

The system presents aggregated analytics data from multiple sensors in a convenient view. Additionally, the system can provide recommendations on the actions to perform based on that data. From there, the admin can create and assign a corresponding service ticket to an operator.

Decision-making

Based on the data provided, the operator schedules the required maintenance activities, and prioritizes them based on each case’s severity.

Why Emerline?

Emerline develops dedicated predictive maintenance tools to meet the unique needs of each business. With streamlined equipment maintenance, you cut costs, reduce downtime, and ensure uninterrupted production workflows. Besides our personal approach to every client, you can see the other cooperation benefits below that differentiate us from competitors.

In-house R&D expertise

We have an expert R&D team of best-in-class Software Engineers, Data Scientists, and Business Analysts who invest 10,000 man-hours in market research and delivery of cutting-edge predictive maintenance solutions. When developing software, we harness the advantages of AI, IoT, ML, Big Data, and other innovative technologies.

Fast MVP delivery

Streamline your solution development with on-time MVP delivery. Within the agreed-upon time, we equip you with a fully working product, allowing you to validate its main features before the active development stage.

ISO certification

Emerline delivers fully compliant predictive maintenance software by adhering to the relevant ISO certifications.

End-to-end development workflows

We can support you through the software delivery process, from discovering your business case and discussing the solution to releasing the product and providing post-release maintenance. Ensure better productivity of your equipment maintenance procedures with Emerline’s comprehensive software development services!

9 offices around the globe

You can contact us 24/7! Emerline’s offices are located worldwide, including the US, the UK, Germany, Poland, and other countries, so you will receive our prompt assistance anytime you need it.

Trusted software development partner worldwide

With over 12 years of experience in custom software development, we are recognizable worldwide. Our strategic partners include Google, Microsoft, AWS and DataBricks.

Are you looking for a reliable predictive maintenance software developer? We are ready to deliver software on time and within budget.

Awards and Recognitions

Through years of productive work with global clientele, including well-established enterprises and Fortune 500 startups, we have achieved the status of a trusted software developer, as you can see from the multiple awards below.
view all awards

What Do Our Clients Say?

With the broad client base we’ve gathered so far, we have a good practice to ask them to share their unbiased feedback on their work with us. Their words are the best proof that we stay on track, delivering quality software on time while working on flexible terms that suit each client most.

4.9

25 Reviews on Clutch

25 Reviews on Clutch

The individuals we work with aren't just contractors, they are an important part of our strategic Team and we enjoy working with them every day!

Tracy B. Neal

President/CEO, CPG Data

Emerline has been the best development partner we’ve ever worked with!

Michael Lynch

CEO, Praxie

We recommend Emerline as a trusted technology partner for developing telemedicine solutions and would choose to work with Emerline again regarding new projects.

Felicity Johnson

Founder, Hello Ralphie

Emerline provided us with the scaling we needed to grow our development capabilities from early-stage POC to now a globally deployed platform in the HR Teach space.

Alex Shubat

CEO, Espresa

We highly recommend Emerline as a technology partner for large and complicated development projects that also delivers continuous cooperation with the provider on new projects.

Dr. Andreas Schwarzer

VP Global IT, FUCHS Group

They consistently delivered items on time, highlighting their commitment to timeliness and organization.

Natalie Boll

CEO, Founder of Tribela GmbH

The level of skill and quality of the developers is outstanding!

Robert Gill

Director, RedWrasse Ltd.

It was noteworthy to highlight the friendly and customer-oriented processes used for product development.

Raphaël Briner

CEO & Founder, Visible

Emerline has enhanced our software to become an indispensable tool for all our staff.

3QC

Business Director, 3QC, Inc.

Emerline helped us build an MVP into a full-fledged production platform — in 14 months

Matt Fruge

Founder and CEO, SquareDash

My experience with Emerline has been great. I highly recommend them to anyone looking for a reliable partner who delivers on time and on budget.

Jesse Sprague

CEO, Echospectra

Throughout our cooperation with Emerline, they proved themselves reliable technology partners.

Renny Joy

IT Director

Frequently Asked Questions

  • What is the difference between predictive maintenance and preventive maintenance?

    Although both terms seem very close in their meaning, the difference between them lies in the approach to maintenance. Predictive maintenance tools use the latest technologies, such as ML, IoT, and big data, which allow for forecasting equipment failures and planning maintenance procedures accordingly. Based on the real-time monitoring of equipment performance conditions, they detect the early signs of malfunctions that indicate potential failures and downtime. On the other hand, preventive maintenance is a general maintenance approach that involves scheduling planned maintenance activities and performing them regardless of the equipment’s condition. Therefore, this approach doesn’t include real-time monitoring.

  • How can predictive maintenance solutions improve sustainability in manufacturing?

    With predictive maintenance solutions, you can lower energy consumption, reduce waste, and extend the equipment's life. This way, you maintain your equipment's optimal working condition and minimize its depreciation, thus preventing downtime and ensuring efficient, uninterrupted operation.

  • Can I apply predictive maintenance software solutions to my legacy equipment?

    Yes, it’s possible, but it may take some time to integrate modern IoT sensors and data collection systems into your legacy equipment. If this is the case, we cut integration times as much as possible by implementing retrofit solutions, such as external IoT sensors and data acquisition devices that collect data from legacy equipment. By combining the collected data with machine learning, you can perform predictive maintenance for older machinery to extend its lifecycle and boost operational efficiency.