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Agricultural Equipment Manufacturer Reduces Machine Breakage by 25% with Coforge’s AI-Powered Predictive Maintenance Solution

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Overview

A global agricultural equipment manufacturer partnered with Coforge to enhance machinery uptime, reduce service costs, and improve customer experience. The company’s reliance on reactive maintenance limited its ability to prevent breakdowns and optimize part usage.

Coforge implemented an IoT-enabled predictive maintenance solution leveraging onboard telematics, edge analytics, and Azure Cloud. The platform provided real-time insights into machine health and part lifecycle, allowing dealers to respond proactively, reduce downtime, and deliver targeted service offers. This transformation helped shift the organization from reactive service to predictive operations, boosting uptime, part sales, and post-sale engagement.

Challenges

A global agricultural equipment manufacturer needed to improve machinery uptime and customer experience while reducing service costs and machine breakdowns. The organization lacked real-time insight into machine health and part lifecycle, relying heavily on reactive maintenance.

Solution

Coforge deployed an IoT-powered analytics solution leveraging onboard telematics, edge analytics, and Azure Cloud to enable:

Predictive Maintenance via IoT:

  • Telematics sensors detected issues and broadcasted them to the cloud
  • A decision rules engine categorized faults and triggered alerts
  • Dealers received early warnings, preventing breakdowns and delays

Proactive Service Offers:

  • Real-time data collection during machine service
  • ML-based model estimated Remaining Useful Life (RUL) of parts
  • Insights powered part promotions and field service outreach

Key Highlights

  • Machine issues detected before breakdown
  • AI-driven part replacement predictions
  • Data-backed marketing outreach campaigns
  • Dealer engagement improved post-sale support

The Impact

  • 25% Reduction in Machine Breakage
  • 15% Fewer Warranty Claims
  • 75% Increase in Over-the-Counter Parts Sales

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