Work

12

Problems we have solved

Representative engagements across the eleven services and six sectors. Each one shows the decision at stake, the measurement and modelling it needed, and what changed.

A representative engagement. The figures are indicative of typical outcomes for this kind of work and are not drawn from a named client.

01Manufacturing and industrial operationsSpain

Predicting drive failures on a cement plant’s mills and kiln

Vibration and motor-current sensing on gearboxes and main drives, fused with process data, gave maintenance teams three to six weeks of warning before bearing and gear faults.

  • 3–6 wkwarning before confirmed faults
  • -71%unplanned drive stoppages, year on year
  • 0missed faults in the pilot year
Read more
Unplanned drive stoppage hours per quarterBeforeAfter
-50050100150200Q1Q2Q3Q4Q1 Before: 62 hoursQ2 Before: 0 hoursQ3 Before: 118 hoursQ4 Before: 41 hoursQ1 After: 18 hoursQ2 After: 0 hoursQ3 After: 0 hoursQ4 After: 46 hours
hoursQ4 · 46 hours
02Manufacturing and industrial operationsGermany

Automated visual inspection of extruded aluminium profiles

A line-scan camera station with controlled lighting and an edge inference unit now grades surface defects at full line speed, replacing sampled manual inspection.

  • 100%of production inspected, at line speed
  • -84%customer-reported surface defects
  • < 40 msinference per frame on the edge unit
Read more
Customer-reported surface defects per monthClaims
-100102030M1M2M3M4M5M6M7M8M9M10M1 Claims: 19 claimsM2 Claims: 17 claimsM3 Claims: 21 claimsM4 Claims: 16 claimsM5 Claims: 14 claimsM6 Claims: 9 claimsM7 Claims: 6 claimsM8 Claims: 4 claimsM9 Claims: 3 claimsM10 Claims: 3 claims
claimsM10 · 3 claims
03Energy and utilitiesFrance

Forecasting heat and electricity demand for a district utility

Hourly forecasts with calibrated uncertainty bands replaced spreadsheet estimates, so the dispatch team now commits plant and purchases balancing energy against a stated confidence level.

  • -52%mean absolute forecast error
  • 89%observed coverage of the 90% interval
  • 48 hhourly horizon, retrained weekly
Read more
Mean absolute error by month, manual versus modelManualModel
051015OctNovDecJanFebMarOct Manual: 8.10 MWhOct Model: 4.20 MWhNov Manual: 10.4 MWhNov Model: 4.90 MWhDec Manual: 12.9 MWhDec Model: 6.10 MWhJan Manual: 13.6 MWhJan Model: 6.30 MWhFeb Manual: 11.8 MWhFeb Model: 5.60 MWhMar Manual: 9.20 MWhMar Model: 4.40 MWh
MWhMar · 4.40 MWh
04Agriculture, water and environmental systemsSaudi Arabia

Optimising pump scheduling across a water transmission network

A hydraulic model and a mixed-integer optimiser schedule pumps against tariff periods and reservoir constraints, cutting energy cost while keeping storage within agreed limits.

  • -16%pumping energy cost
  • -38%pump starts per day
  • 0reservoir limit breaches in 9 months
Read more
Monthly pumping energy cost, indexed to baselineBaselineOptimised
020406080100M1M2M3M4M5M6M1 Baseline: 100 indexM1 Optimised: 96 indexM2 Baseline: 100 indexM2 Optimised: 90 indexM3 Baseline: 100 indexM3 Optimised: 86 indexM4 Baseline: 100 indexM4 Optimised: 84 indexM5 Baseline: 100 indexM5 Optimised: 83 indexM6 Baseline: 100 indexM6 Optimised: 84 index
indexM6 · 84 index
05Buildings and infrastructureFrance

Continuous structural monitoring of a motorway viaduct

Strain, acceleration, displacement and temperature sensing with custom acquisition nodes gives the structural engineer a modal and strain history that separates traffic and thermal effects from real change.

  • 48synchronised channels on 6 nodes
  • < 0.2%data loss over 12 months
  • 1bearing fault confirmed and scheduled
Read more
First vertical mode frequency, temperature-correctedCorrected
2.382.392.402.412.42JanFebMarAprMayJunJulAugSepOctNovDecJan Corrected: 2.41 HzFeb Corrected: 2.41 HzMar Corrected: 2.40 HzApr Corrected: 2.41 HzMay Corrected: 2.40 HzJun Corrected: 2.40 HzJul Corrected: 2.39 HzAug Corrected: 2.39 HzSep Corrected: 2.40 HzOct Corrected: 2.40 HzNov Corrected: 2.41 HzDec Corrected: 2.40 Hz
HzDec · 2.40 Hz
06Buildings and infrastructureUnited Arab Emirates

Energy performance across a commercial building portfolio

Metering, building management and weather data were unified for 27 buildings, and calibrated building models now rank retrofit options by verified saving rather than by estimate.

  • 27buildings on one data foundation
  • 5 of 6retrofits within modelled saving range
  • -11%portfolio energy intensity, year one
Read more
Modelled versus measured saving, first retrofit roundModelledMeasured
05101520B1B2B3B4B5B6B1 Modelled: 14 %B1 Measured: 13 %B2 Modelled: 9 %B2 Measured: 10 %B3 Modelled: 18 %B3 Measured: 16 %B4 Modelled: 7 %B4 Measured: 8 %B5 Modelled: 12 %B5 Measured: 11 %B6 Modelled: 10 %B6 Measured: 6 %
%B6 · 6 %
07Transport, logistics and supply networksSpain

Routing and scheduling for a regional distribution fleet

A vehicle routing optimiser with time windows, vehicle types and driver rules produces daily plans that planners adjust, reducing kilometres and overtime while keeping delivery windows.

  • -11%kilometres per delivery
  • -33%driver overtime hours
  • < 5 minto produce a daily plan for 38 vehicles
Read more
Kilometres per delivery by monthBeforeAfter
88.5099.501010.5M1M2M3M4M5M6M1 Before: 9.60 kmM2 Before: 9.80 kmM3 Before: 9.50 kmM4 Before: 9.90 kmM5 Before: 9.70 kmM6 Before: 9.60 kmM1 After: 9.10 kmM2 After: 8.80 kmM3 After: 8.60 kmM4 After: 8.60 kmM5 After: 8.50 kmM6 After: 8.60 km
kmM6 · 8.60 km
08Energy and utilitiesQatar

A sensing node for high-temperature, dusty plant environments

A custom acquisition and processing node, from schematic to verified prototypes, measures vibration and temperature on equipment where off-the-shelf devices had failed, and computes indicators locally.

  • 85 °Ccontinuous ambient rating
  • > 18 mobattery life at the agreed reporting rate
  • 3design iterations to a production-ready board
Read more
Measured battery voltage over the field trialNode A
3.453.503.553.603.653.70M0M1M2M3M4M5M6M0 Node A: 3.65 VM1 Node A: 3.62 VM2 Node A: 3.60 VM3 Node A: 3.58 VM4 Node A: 3.57 VM5 Node A: 3.55 VM6 Node A: 3.53 V
VM6 · 3.53 V
09Manufacturing and industrial operationsLebanon

A discrete-event twin of a bottling line

A simulation calibrated to machine event logs showed where throughput was really lost and let management test buffer, speed and maintenance options before buying a new filler.

  • +14%throughput from buffer and speed changes
  • < 3%model error against measured output
  • Deferredfiller purchase, pending demand
Read more
Simulated throughput by scenarioThroughput
010,00020,00030,000As isNew fillerBuffersBuffers + speedsAll threeAs is Throughput: 21,400 bottles/hNew filler Throughput: 22,100 bottles/hBuffers Throughput: 23,300 bottles/hBuffers + speeds Throughput: 24,400 bottles/hAll three Throughput: 25,100 bottles/h
bottles/hAll three · 25,100 bottles/h
10Agriculture, water and environmental systemsSpain

Irrigation scheduling from soil sensing and imagery

Soil moisture profiles, weather and satellite imagery feed a water-balance model that recommends irrigation per block, validated against yield and water use over two seasons.

  • -21%irrigation water per hectare
  • ±0%yield difference against matched blocks
  • 140hectares scheduled by season two
Read more
Water applied per hectare by month, season twoCalendarScheduled
02505007501,0001,250AprMayJunJulAugSepApr Calendar: 310 m³/haMay Calendar: 520 m³/haJun Calendar: 780 m³/haJul Calendar: 960 m³/haAug Calendar: 910 m³/haSep Calendar: 540 m³/haApr Scheduled: 250 m³/haMay Scheduled: 420 m³/haJun Scheduled: 610 m³/haJul Scheduled: 760 m³/haAug Scheduled: 720 m³/haSep Scheduled: 430 m³/ha
m³/haSep · 430 m³/ha
11Energy and utilitiesBahrain

Feasibility of condition monitoring for a compressor fleet

A structured feasibility study with a short measurement campaign told the client which compressors justified monitoring, which sensors to use and what the programme would cost, before any vendor was engaged.

  • 14 of 31compressors where monitoring changes decisions
  • 2 wkmeasurement campaign
  • -40%programme cost against the broadest vendor offer
Read more
Compressors by monitoring recommendationMachines
02.5057.501012.5Phase 1Phase 2Periodic onlyRun to failurePhase 1 Machines: 8 machinesPhase 2 Machines: 6 machinesPeriodic only Machines: 11 machinesRun to failure Machines: 6 machines
machinesRun to failure · 6 machines
12Financial and commercial operationsGermany

Detecting billing anomalies in a services business

Contract, work-order and invoice data were reconciled, and an anomaly model now flags unbilled work and pricing errors for review each week, with a governance process for the model itself.

  • 1.9%of revenue identified as leakage
  • 73%of flagged items confirmed by analysts
  • Weeklyreview cycle owned by the finance team
Read more
Flagged items confirmed per weekConfirmed
020406080W1W2W3W4W5W6W7W8W9W10W11W12W1 Confirmed: 31 itemsW2 Confirmed: 44 itemsW3 Confirmed: 52 itemsW4 Confirmed: 48 itemsW5 Confirmed: 39 itemsW6 Confirmed: 35 itemsW7 Confirmed: 30 itemsW8 Confirmed: 27 itemsW9 Confirmed: 24 itemsW10 Confirmed: 22 itemsW11 Confirmed: 21 itemsW12 Confirmed: 19 items
itemsW12 · 19 items

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