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A Commercial Vehicle Manufacturer Used AI for Predictive Maintenance and Saved 43% Warranty Repair Cost

About Our Client

Our client is a global leader in the commercial vehicle manufacturing industry. For over two decades, they have been manufacturing high-performing trucks, buses, engineering components, and power solutions in their country-wide facilities. These vehicles and solutions are fuelling the economies of many countries across the globe.

The Need

Reliable commercial vehicles are the lifeblood of many businesses’ operations. Even a single unexpected breakdown can lead to costly repairs and significant disruptions. To minimize these risks and reduce costs, our client relies on traditional telematics systems to monitor the health of their entire fleet.

While these systems provide valuable updates on vehicle performance and allow for scheduled maintenance, they primarily focus on identifying existing issues rather than predicting future failures. This reactive approach increased vehicle downtime, and technician workloads, and limited the personalized service offerings to the customers.

Our Solution

Softude created an AI solution for predictive maintenance in manufacturing that provides a real-time view of the health and performance of vehicles. It works on 10^8 records per day including both historical and real-time contextual data on various parameters such as engine temperature and fuel consumption.

Analyzing this huge amount of data gave insights into which vehicle models and their components or parts require immediate maintenance and also those that will wear out in the future. The maintenance team gets this info as early as 3 weeks so that they can prevent those issues from halting vehicles' operation.


  • 98% accuracy in predicting failures.
  • 12,000 hours of downtime saved in 3 months.
  • Saved 43% cost on warranty repairs and maintenance.
  • Now, they can offer tailored maintenance plans to their customers with data-driven insights on vehicles’ health and safety.

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