Web-Based Maintenance Prediction of Machine Conditions and Failure Modes Using Machine Learning

Abstract

Machine failure may result in unplanned downtime, production losses, safety risks, and increased costs. Hence, predicting machine failures is a significant challenge faced by many industries. Predictive Maintenance (PdM) techniques can help mitigate these risks by predicting machine failures before they occur. This research, therefore, develops two supervised Machine Learning (ML) algorithms to predict failure conditions and the associated failure modes for a milling machine. Six machine features were investigated. The ML models were then developed using a four-stage process including data pre-processing, training, evaluation, and deployment. Several ML algorithms were applied then the results were evaluated using accuracy, recall, precision, and [Formula: see text]1-score. The results showed that the Random Forest algorithm was the most effective in predicting machine conditions and failure modes of the milling machine. A web application for PdM was finally developed and tested for the PdM of the milling machine. In conclusion, the developed web application including ML algorithms can support the effective PdM for the machine, which leads to enhancing its availability and improving productivity. Future research considers adopting ML algorithms for predicting machine conditions and failure types of other machines.