PLANT RELIABILITY.
Equipment Faults + Process Anomalies
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PlantOS™ Prescriptive AI.
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3 outcomes in 1 prescription — zero guesswork.
Acted Upon
Prediction Accuracy
Savings
FROM NOISE
TO OUTCOMES.
Mechanical Faults
Vibration, coupling defects & misalignment
Physics + AI models detect coupling defects, structural looseness, and base rigidity issues across Banbury Mixer gearboxes, Triplex Extruder motors, and Calender Roll drives before they cascade into unplanned downtime.
Electrical Faults
Motor overheating &
cooling failures
Temperature trend analysis at motor DE and NDE bearings surfaces cooling fan reversals, lubrication failures, and load imbalances before they trip extruder motors and mixer drives across tire production lines.
Process Induced Faults
Parameter drift &
production deviation
Continuous monitoring across Banbury Mixers, Hold and Feed Mills, Duplex–Triplex Extruders, 4 Roll Calenders, Tyre Building, and Curing systems detects process shifts before they cost tons of production across high-load tire manufacturing.
14 areas. 71 critical assets. One Single Source of Truth.
How JK Tornel unified its tire plant — 167 total assets across mixing, milling, extrusion, calendering, tyre building, and curing — into a single contextualized source of truth.
Contextualization layerPhysics + AI: precision that predictions can't match
PlantOS™ doesn't flag anomalies. It traces root cause — across mechanical, electrical, and process domains — with 100% prediction accuracy and zero missed faults.
Intelligence layerDiagnostic → Recommendation → Action
48 prescriptions acted upon. 66.45% implementation rate, building toward 90%+ adoption through expert training. Real Diagnostic Reports with specific corrective steps — not dashboards, not alerts. Work orders that close.
Prescriptive engineOutcomes the plant's own operators signed off on
376 hours of unplanned downtime recovered. 108-hour MTBR achieved on production line. $46,245 in annual maintenance savings realized. All figures from JK Tornel's own Maintenance & Operations teams.
Validated outcomesPrediction
≠
Outcomes.
Most AI deployments stop at the alert. They predict. They visualize. They dashboard. But prediction without a closed loop is just a more expensive alarm bell.
JK Tornel’s deployment with PlantOS™ proves the gap isn’t in the model — it’s in the mile between insight and action. The 99% Trust Loop™ is what bridges it.
PlantOS™ has consistently been very helpful. Its precise vibration alerts and clear prescriptive recommendations, like the one for Gearbox 2 on our Banbury mixer to make corrective alignment, have enabled us to act quickly and prevent major downtime.
Mr. Carlos Guzman
Banbury Mixers Area Maintenance Supervisor, JK Tornel, Mexico
GET THE COMPLETE PICTURE.
Real PlantOS™ Diagnostic Reports from live JK Tornel deployments (Banbury Mixer 6, Tri Extruder Line2-90MM)
Equipment-level fault detection across mechanical, electrical & process domains
The 99% Trust Loop™ framework — step by step
User-validated outcome data, confirmed by JK Tornel's own maintenance team
Infinite Uptime · 881 plants · 26 countries · Production Outcomes. Delivered.
Thank you for your interest in
PlantOS™ Prescriptive AI.
Enter your official work email to unlock specs delivering
3 outcomes in 1 prescription — zero guesswork.