Solutions
PlantOS™ Prescriptive AI

Prescriptive Maintenance Solutions
for Plant Reliability.

One Vertical AI platform. A purpose-built AI solution for every equipment class in your plant, organised by industry and deployed in weeks.

PlantOS™ delivers prescriptive maintenance as three solutions, for all equipment in a heavy manufacturing plant. Where generic tools raise alerts, PlantOS™ issues a prescription: the specific component at fault, the corrective action, and the outcomes to be achieved. Operators validate every prescription, so the AI learns from real outcomes across 1000 plants.

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The PlantOS™ Advantage

Plant
Reliability

The umbrella outcome: less downtime, lower maintenance cost, and longer equipment life across every line.

Equipment-Specific
Intelligence

Each solution is pre-trained on thousands of failure signatures for that exact equipment class, not on a generic model.

Quantified
ROI

Every prescription forms a closed loop, where operator validations are translated into avoided downtime costs for documented board-level reporting.

Enterprise Agent
Orchestration

Powers your corporate AI assistants natively, enabling management to instantly query fleet intelligence and auto-generate executive reports.

EQUIPMENT-SPECIFIC AI

What are the three PlantOS™ prescriptive maintenance solutions?

One platform, three solutions, sized to what each asset is worth.

Infinite Uptime's PlantOS™ covers the full criticality spectrum, from the flagship equipment that defines your output to the balance of plant that has never been monitored at all.

Equipment-specific AI protects the machines that can stop production. Wired and wireless coverage scales across everything else. A single risk model underneath turns all of it into maintenance, spares and CAPEX decisions.

Where generic tools raise alerts, PlantOS™ issues a prescription: the component at fault, the corrective action, and the outcome to be achieved.

A rotary kiln and an overhead travelling crane enclosed under a glass dome behind an AI Shields barrier.

01 · The Active Defense

AI Shields

Equipment-specific AI for the machines that can stop production.

Each AI Shield is trained on a single class of production-critical equipment, so it tells a mechanical fault apart from a process upset instead of flagging both as noise. Dynamic FMEA correlates live mechanical signals with real process conditions, which surfaces failure modes that appear only when heat, load or chemistry change.

Shields in service

  • Steel
  • Cement
  • Tire & Rubber
  • Pulp & Paper
  • Metals & Mining
Explore AI Shields

02 · The Foundation

Flex Reliability

Coverage for the rest of the plant, sized to what each asset is worth.

Not every machine justifies the same sensing. Flex Reliability lets you match the technology to the consequence of a stoppage, from wired piezoelectric on assets that halt a line to self-powered wireless tags on equipment that has never carried a monitoring budget. Existing third-party sensor data is ingested as it is, so there is no rip and replace.

Three coverage tiers

Explore Flex Reliability
Cement, steel, oil and gas and mining sites feeding streams of data into a single glowing core labelled Plant Fusion.

03 · The Orchestration Layer

Plant Fusion

One risk model behind every maintenance, spares and CAPEX decision.

Asset signals roll up through equipment, process, plant and fleet into one risk foundation of failure probability, consequence and MTBF, ranked by RBI, RCM and FMEA. Open API and MCP carry each prescription into the systems that execute the work, and every job an operator closes returns as a label that sharpens the next decision.

Three decisions, one foundation

  • MaintainA dynamic, ISO-aligned PM programme driven by failure mode, not by calendar date.
  • StockRisk-aligned min and max levels with ordering triggers, safety-critical items always human-gated.
  • InvestCAPEX backed by failure-probability forecasts and remaining-life estimates.
See Plant Fusion

An AI Shield for every production-critical asset

Ten Shields across five verticals, each trained on one class of equipment. Select a vertical, then open a Shield to see what it watches, the faults it detects and what it has protected.

Dynamic FMEA, 24x7 human-in-the-loop CoE review

*Production protected is calculated on the customer's own stated hourly value of output for the affected line.

No blind spots, no orphan assets.

Deep domain AI on the equipment that defines your output, flexible coverage across everything that supports it, and one risk model that turns all of it into decisions your board can read.

Compounding Intelligence

Why does the outcome gap widen instead of closing?

Zero Guesswork. Compounding Intelligence. Starts Day 1.

Infinite Uptime retraining across 1000 plants
Horizontal platforms static local models drift over time

The Structural Cause

Compounding intelligence through the 99% Trust Loop

PlantOS™ - the Prescriptive Al that learns continually across the entire installed base. Operator validation turns every correction into shared intelligence, so each asset teaches every other. Horizontal platforms rely on static local models that drift over time. Because PlantOS™ retrains across 1000 plants, drift is caught before it compounds, and accuracy improves the longer the system runs.

IMPLEMENTATION

How long does it take to
deploy PlantOS™ Prescriptive AI?

The Path to Reliability Outcomes Your Operators Trust - in 90 Days

No rip-and-replace works with your existing systems.
First prescription in 2 weeks. Scale with confidence.

Week 1-2

Solution Deployment

  • 100% equipment coverage Day 1
  • Rotating + static equipment + process context
  • Baseline assessment complete

Week 3-4

First Prescription

  • Operator validation workshop
  • Digital signoff trained
  • First fault prescribed

Month 2

Scale & Optimize

  • Additional equipment lines
  • Process efficiency modules
  • KPI baseline established

Month 3

Plant-Wide

  • Board-ready ROI report
  • Expansion planning
  • 99% Trust Loop complete

Ready to see your first prescription?

Book a discovery call. We'll model your specific equipment risk and ROI before you commit.

Try PlantOS™

Frequently Asked Questions

01 What is prescriptive maintenance and how is it different from predictive maintenance?

Predictive maintenance forecasts that a machine is likely to fail and roughly when. Prescriptive maintenance goes further: it identifies the specific component at fault mapping both mechanical and process-induced faults, prescribes the corrective action, and highlights the guaranteed outcomes. PlantOS™ then captures whether the fix worked, so its recommendations improve with every validated outcome.

02 What is Dynamic FMEA in prescriptive maintenance?

Dynamic FMEA is the method behind AI Shields. A traditional Failure Modes and Effects Analysis is a static document, written once and quickly outdated. Dynamic FMEA continuously correlates live mechanical signals with real process conditions, so it detects failure modes that appear only when heat, load or chemistry change. That is how PlantOS™ identifies faults such as thermal fatigue and cyclone jamming that generic vibration monitoring cannot see.

03 Does Infinite Uptime's solution require replacing existing equipment?

No. PlantOS™ requires no rip-and-replace. Sensors are retrofitted onto your existing equipment and PlantOS™ works alongside the systems you already run. Most plants receive their first prescription within two weeks of installation.

04 What equipment does the AI Shield Prescriptive Maintenance Solution support?

AI Shields are built for flagship heavy industrial equipment, specifically kilns, mills, cranes, furnaces, dryers, etc. Each Shield is trained on the failure signatures of that exact equipment class and detects both mechanical and process-induced faults including thermal fatigue, material build-up, cyclone jamming, oil contamination, gear-mesh backlash, and more.

05 Which PlantOS™ solution is right for my equipment?

It depends on asset criticality and operational scope. AI Shields protect flagship, production-critical machinery - such as kilns, rolling mills, and cranes - by correlating live mechanical signals with process parameters to detect complex, condition-specific failure modes. Flex Reliability delivers standardized wired and wireless coverage across the rest of your plant's rotating assets. Underpinning both is Plant Fusion, which aggregates asset intelligence into a unified risk model, translating line-level prescriptions into plant- and fleet-wide maintenance, spares, and CAPEX decisions. Together, they span the complete criticality spectrum without requiring a patchwork of standalone tools.