Predictive Maintenance

Industrial process monitoring is fundamental to the safety and economic performance of modern process plants. Current practice remains a one-task-one-model paradigm that is label-inefficient and prone to degradation under operating drift. Foundation models have reshaped language, vision, and generic time-series forecasting, but it has not been adapted to industrial process monitoring. This setting poses domain-specific challenges, including safety-critical decisions and asymmetric sampling between process variables and laboratory measurements. We propose the industrial process monitoring foundation model (IPM-FM). It first learns general-purpose representations from unlabeled industrial process data through self-supervised pretraining, then adapts to specific monitoring tasks using a small amount of task-labeled data, and finally produces calibrated predictions through an uncertainty-aware prediction head. IPM-FM integrates a self-supervised Informer backbone with a multi-criteria consensus feature selector, a recursive lag-feature regression head, and a calibrated Monte Carlo dropout uncertainty module. On a seven-year hydrotreater dataset for diesel flash-point soft sensing, IPM-FM attains an RMSE of 2.99, $R^2$ of 0.50, and 97% coverage of its 95% predictive interval, outperforming the strongest classical and from-scratch sequence baselines by 8.3% and 14.6% in RMSE respectively, supporting the viability of a unified pretraining--adaptation framework for industrial process monitoring.

In data-driven predictive maintenance (PdM), feature extraction is usually treated as fixed preprocessing: a descriptor set is chosen once and reused while the downstream model or forecasting horizon changes. This paper isolates the representation-learning stage and presents a quantile-led feature-extraction framework based on a dual-stage MLP-QRNN hierarchy. QRNN1 learns a broad ten-quantile conditional distribution for each sensor channel, while skip-connected QRNN2 refines a retained mid-tail quantile set into compact, channel-resolved, distribution-aware features. A fixed thirteen-pipeline ablation spans 1-hour, 70-hour, and 30-day regimes across 72 machines in 9 industrial facilities, with the downstream temporal classifier held fixed within each regime. Increasing the retained mid-tail set from two to four quantiles improves 30- and 60-minute F1-score, reaching 75.92% and 72.44% with attention enabled. The results also show that representations do not transfer reliably beyond their design horizon unless feature capacity, temporal embedding, activation strategy, and sensor breadth are scaled with the forecasting task. The unmodified short-horizon extractor falls to 42.90% F1 at 70 hours, whereas horizon-conditioned extractors reach 60.38% at 70 hours and 79.97% at 30 days. The framework therefore supports treating PdM feature extraction as a horizon-dependent representational stage rather than fixed preprocessing.

Long-horizon predictive maintenance requires models to distinguish slowly evolving degradation from normal operating-regime variation over planning windows measured in days rather than hours. This paper evaluates whether an explicit conditional-quantile representation provides an informative classifier interface for this problem. The proposed TQRNN30d framework combines a dual-stage quantile regression neural network (QRNN) feature extractor with a multi-stream temporal fusion classifier. Each hourly word of 81-channel machine behaviour is mapped to a 324-dimensional quantile-state representation, and 720 ordered hourly words form the 30-day document supplied to the long-horizon model. The classifier fuses quantile states with dynamic covariates, channel-level static metadata, and a 168-hour latent-history stream using gated residual processing, causal recurrent encoding, and metadata-conditioned cross-modal attention. A bounded instability-aware signal derived from sustained one-word-ahead prediction-error divergence provides auxiliary memory modulation at the longest horizon. Evaluation uses a machine-disjoint 43/14/15 train/validation/test allocation across 72 machines in nine manufacturing facilities. At 30 days, TQRNN30d achieves 79.97% F1, 80.18% recall, 81.82% precision, 82.39% accuracy, and 0.820 ROC-AUC. It leads all 18 evaluated baselines at the 7-, 14-, and 30-day fixed-threshold comparisons, with the largest F1 advantage at 14 days. The results support held-out-machine performance within the observed homogeneous nine-facility fleet, but do not establish unseen-site, cross-equipment, or cross-sector generalisation.

Monitoring the health of heterogeneous industrial robot fleets is severely challenged by the multi-modal nature of their operational cycles and a persistent scarcity of run-to-failure data. Standard data-driven approaches, particularly deep learning architectures relying on sequential reconstruction, often struggle in this specific setting; they tend to over-smooth complex dynamics, masking early signs of degradation. To address these industrial constraints, we reframe the monitoring problem through a framework based on Phase Space Reconstruction (PSR). Instead of predicting temporal sequences, this framework transforms univariate sensor data into a geometric attractor, explicitly unfolding the mechanical states independently of their temporal occurrence. By evaluating various anomaly scoring techniques within this space, we demonstrate that discrete support estimation provides an effective and computationally frugal Health Indicator (HI). Validated on a real-world dataset of 21 heterogeneous robots over three years and a synthetic Langevin system, our approach outperforms standard deep learning baselines. We show that aligning the algorithmic bias with the geometric properties of the target system yields a pragmatic, traceable and easily deployable approach perfectly tailored to the realities of industrial constraints.

Tool wear prediction is an important task in CNC machining, where accurate monitoring of tool condition supports product quality and process reliability. Machine learning methods have shown potential for this task, but their use in industrial environments is limited by the distributed nature of machining data and by restrictions on data sharing between machines, sites, or organizations. Federated learning offers a suitable framework for this setting by enabling collaborative model training without transferring raw operational data. This paper investigates federated learning for CNC tool wear prediction. Tool trajectories are distributed across simulated clients to represent a federated learning scenario. The federated models are compared against centralized references and local client baselines. Results show that federated learning achieves performance close to centralized learning and improves significantly over local client models. These findings indicate that federated learning can support collaborative tool wear prediction in distributed CNC manufacturing environments.

Vision Transformers (ViTs) are widely believed to require more labeled data than CNNs for industrial dense prediction. Through controlled experiments on four industrial datasets, we show that the data-efficiency gap stems from pretraining incoherence, which refers to the statistical mismatch between ImageNet-pretrained ViT backbones and COCO-pretrained CNN necks, rather than from inherent self-attention deficits. We characterize the cross-architecture feature gap and propose a lightweight AlignBlock family for pyramid-level feature recalibration. Our core finding empirically identifies a data-efficiency frontier: for domain-proximal scenes with >= 200 samples, Swin-Graft surpasses YOLOv11x (terminal 703-shot: 0.973 vs 0.956 mAP@50); for domain-distant scenes, CNNs retain advantage (hook 141-shot: 0.900 vs 0.600 mAP@50). Grafted neck weights yield up to 2.5x the mAP of a randomly initialized neck.

Predicting failures before they occur remains a major challenge in predictive maintenance, particularly when failures are rare, when equipment of the same family differ in sensor configurations, and when the goal is anticipation rather than diagnosis of an already observed fault. This paper proposes a common-to-target probabilistic model that learns shared failure-related patterns across a family of heterogeneous equipment and adapts parsimoniously to target equipment. The model explicitly accounts for sensor heterogeneity, operating context, and degradation dynamics to produce calibrated failureprobability estimates suitable for maintenance planning. Its performance is evaluated on a synthetic refrigerator dataset comprising 27 simulated refrigerators with varying sensor configurations, operating conditions, and failure types, providing a controlle

Raman spectroscopy enables non-destructive, label-free molecular characterization across materials science, biomedicine and process monitoring. Predictive Raman datasets often contain few labelled spectra and thousands of ordered wavenumbers, with informative variation within bands and across distant spectral regions. Latent-variable chemometrics accommodates collinear small-sample data but can obscure fine peak morphology, whereas deep spectral networks resolve this structure only after task-specific training. TabPFN avoids task-specific parameter fitting through pretrained in-context inference, but processes very wide inputs as feature-subsampled views that do not preserve joint visibility of related bands. We present RamanPFN, a spectral representation framework that encodes these dependencies before TabPFN inference. Global Compositional Unmixing constructs non-negative coordinates over the complete spectrum so that distant bands with shared latent variation occupy a common predictive axis. Local Vibrational Subspace Encoding represents contiguous wavenumber regions with multiple orthogonal modes that retain independent changes in peak shape, intensity and position. The representations are evaluated separately and combined at the prediction level. Evaluation covered 150 tasks from 74 public Raman datasets. RamanPFN reduced root-mean-square error by 19.6% on average across 129 regression targets relative to direct TabPFN inference and further reduced the remaining classification error by 9.0% across 21 classification tasks. These results establish explicit spectral representation as an effective interface between high-dimensional Raman measurements and reusable tabular inference.

To improve the operational readiness of combat aircraft engines and reduce unplanned maintenance costs, accurately estimating the remaining useful life (RUL) is critical. Traditional maintenance often proves insufficient under dynamic mission profiles. In this study, a deep learning-based predictive maintenance model capable of autonomously extracting features from multivariate sensor data was developed. Using the NASA C-MAPSS FD001 and FD004 datasets, data were converted into sequential blocks via 50- and 30-step sliding windows, respectively. The model's architectural superiority in autonomously extracting temporal degradation features was validated against RF, CNN-LSTM, and BiLSTM baselines. On FD001, it achieved an R-squared (R2) of 0.8901, a 13.28 RMSE, and a 320.34 NASA risk score, demonstrating generalizability on the multi-regime FD004 dataset with a 15.71 RMSE. The proposed maintenance protocol achieved a 0.9973 AUC at the critical 30-cycle threshold, ensuring high reliability. Additionally, a decision-support simulator has been developed to validate this protocol under aggressive combat flight profiles.

Digital twins have emerged as a foundational technology within the context of Industry 4.0, offering a paradigm for the real-time virtual representation of physical systems. However, managing their growing complexity, particularly in distributed industrial environments, requires intelligent architectures capable of autonomous decision-making, dynamic adaptability, and inter-agent coordination. This systematic review explores the intersection between Multi-Agent Systems and Digital Twins, with a particular focus on predictive maintenance applications in resource-constrained contexts. Through a critical analysis of over 547 papers published in high-impact journals (IEEE Transactions, Nature, Elsevier, MDPI), we establish a taxonomy of existing hybrid architectures, identify persistent technological bottlenecks, and formulate three open research questions concerning: (i) the deployment of artificial intelligence on resource-constrained microcontrollers, (ii) distributed multi-node coordination via lightweight communication protocols, and (iii) the hierarchical orchestration of Digital Twins toward smart factory control integrating residual life estimation and explainable Artificial Intelligence. The results of this analysis reveal that, despite significant progress, no existing system offers an integrated embedded-distributed hierarchical solution that simultaneously meets the requirements of Industry 5.0.

Supervised learning models in the predictive maintenance field are regularly trained on highly imbalanced industrial datasets: machine failures occur rarely but have a disproportionate effect on operations. In addition to the clear class disparity, failure data are typically non-homogeneous, with different failure modes arising from distinct physical processes and exhibiting a multimodal distribution across minorities and classes. Traditional imbalance-management methods, e.g., undersampling, SMOTE-based interpolation, or cost-sensitive learning, typically assume that the minority population is homogeneous. This means their effectiveness is severely limited in the multifaceted conditions encountered in industrial practice. This paper determines the possibility of a failure-type-conscious generative augmentation program to improve the identification of infrequent failures in predictive maintenance systems. An experimental design that is leakage-safe is used to compare five imbalance-handling methods: cost-sensitive learning, random undersampling, SMOTE oversampling, single-generator GAN augmentation, and a specialized multi-generator GAN architecture that has independent generators that are asked to learn individual failure subtypes. Precision/Recall-oriented measures are used to quantify model performance; the main evaluation measure is the PR-AUC. Experiments conducted on the AI4I 2020 predictive maintenance dataset indicate that the proposed multi-generator GAN framework produces more realistic minority samples, yielding higher PR-AUC and recall scores compared to traditional resampling methods and individual-generator GAN augmentation.

Open-access datasets for marine-engine predictive maintenance remain scarce, particularly those from controlled fault experiments with documented operating conditions, subsystem-level interventions and system-level measurements. This work presents the Marine Engine Fault Dataset, an openly available dataset from a turbocharged, intercooled three-cylinder marine diesel engine operated on a testbed under both reference and fault-scenario conditions. The experimental campaign combined a reference-performance program across the 30-90% load range with scenario-based tests in which abnormal conditions were introduced after stabilized fault-free operation, enabling controlled comparison between baseline and fault-affected behaviour. Five anomaly classes were implemented through physical interventions affecting major engine subsystems: cooling-water pump cavitation, compressor air-filter clogging, air-cooler fouling, injection-valve nozzle clogging and turbine degradation induced through increased exhaust-side restriction. The released data comprise multi-sensor time-series of operating, thermal, pressure, flow and combustion-related variables, with a separate reference-performance record and metadata for structured reuse. Technical validation shows that the reference measurements remain physically coherent across the operating range and that the imposed anomalies produce interpretable response patterns consistent with the affected subsystems, including progressively distinguishable behaviour where different severities were implemented. By combining controlled fault realization, multi-load operation and system-level measurements within a real marine-engine platform, the dataset provides a well-documented benchmark for anomaly detection, fault diagnosis, degradation modelling and related condition-monitoring studies in maritime machinery.

Predictive maintenance relies on accurate Remaining Useful Life estimation, often formulated using survival analysis over multivariate time-series data. While modern deep survival models achieve strong predictive performance, their black-box nature limits their use in safety-critical settings where actionable insight is required. In this work, we introduce \textit{SurvCF(t)}, the first framework for generating counterfactual explanations for survival models operating on time-series data. \textit{SurvCF(t)} identifies minimal, plausible, and temporally consistent changes to an asset's operational history that increase its predicted life time, framing explanation as a constrained optimization problem combining validity, proximity, sparsity, and plausibility. We evaluate the method on multiple benchmarks, including C-MAPSS, N-CMAPSS, and a real-world case study of the Scania Component_X dataset, demonstrating its ability to produce actionable and interpretable interventions. Our results show that \textit{SurvCF(t)} bridges the gap between survival prediction and prescriptive maintenance, enabling explainable and decision-oriented AI for maintenance strategies.

Multi-task deep learning models that jointly perform fault classification and remaining useful life (RUL) regression are increasingly used in predictive maintenance, yet reported performance can be strongly affected by how sliding-window sequences are split into training and test sets. We investigate this issue using AMTLNet, an attention-enhanced multi-task architecture, on three public benchmarks: NASA C-MAPSS, NASA IMS, and the UCI Hydraulic System dataset. We show that naive splitting can inflate classification accuracy from a genuine 20-60 percent to 99.9 percent, or reduce it to 0 percent through degenerate class representation. To address this, we introduce a chunk-based, leakage-audited splitting protocol and evaluate all models using five seeds, one-way ANOVA, and Tukey HSD tests. On C-MAPSS, with 19,976 leakage-free training windows, AMTLNet matches a single-task CNN-LSTM baseline in classification, achieving 84.12 +/- 0.96 percent accuracy with Tukey p = 1.0, and reaches an R2 of 0.86 +/- 0.01 while significantly outperforming a naive multi-task baseline. On the smaller Bearing and Hydraulic datasets, multi-task training is unstable, but the failure mode differs: classification degrades for Bearing, whereas regression degrades for Hydraulic. We relate this asymmetry to label provenance and propose a practical framework for deciding when joint training is appropriate under data scarcity. Ablation results show that the multi-head attention branch is the main contributor to regression stability. Removing it reduces R2 from 0.861 to 0.766 and more than doubles classification variance, whereas the convolutional branch contributes little to regression despite using about one-third of the parameters. This study contributes a reusable leakage-audit protocol, seed-transparent evaluation, and evidence that task-specific stability depends more on label provenance than on task type.

Process industries rely on time-series forecasting and soft sensing to estimate quality variables that are hard to measure online. Labeled data are scarce, operating regimes change frequently, and retraining models or rebuilding alignment pipelines for each scenario is costly. Such settings often provide variable tables and process documents that record variable names, units, physical meanings, and process roles. However, standard time-series backbones usually treat inputs as anonymous numerical columns. Existing text-enhanced methods also rarely make the semantic-logical relations between input variables and the prediction target available to the model within each numerical window. To address this problem, this article proposes Task-Semantic Field Factorization (TSF), a large language model (LLM)-guided framework. TSF builds a task-semantic field from task protocols and variable documents before training and uses the LLM only for offline semantic construction. Online training and inference remain with conventional time-series backbones. During training and inference, the current numerical window activates variable semantics, so semantic information participates in each prediction and supports adaptation to different prediction targets and operating shifts. On multiple complex industrial forecasting and soft-sensing tasks, TSF reduces MAE by 6.4% on average in improved settings, with the largest reduction reaching 25.5%. It adds only about 1.8--3.0k parameters, with less than 0.008 ms/step of additional online inference overhead. These results show that TSF turns existing process documents into measurable forecasting gains across backbones and semantic generators while remaining lightweight for deployment.

Industrial prediction and soft sensing depend on credible input measurements. In field deployment, a predictor may receive biased, delayed, stale, or derived measurements that still look plausible. Prediction can then fail before the forecasting backbone becomes the main limitation, because the input window no longer represents the real process. Sensor reconstruction, data reconciliation, and fault-tolerant soft sensing reduce this risk, but they often rely on numerical correlation, alarms, fault labels, or explicit process equations. These assumptions are not always available. A correlated variable can also be an unsafe reference when variables share instruments, derived formulas, soft-sensing chains, or control actions. The key issue is to decide before prediction which external measurements can credibly support the current measurement. To address this issue, this article proposes LLM-Guided Measurement Credibility Correction (MCC). MCC converts measurement meanings in process documents into measurement semantics usable by numerical models. It builds independent process references from semantically qualified external measurements and corrects local measurement conflicts before prediction. The predictor therefore receives a more credible input window. Across multiple complex industrial forecasting and soft-sensing tasks, +MCC achieves average relative MAE reductions of 30.7% on real-test protocols and 80.3% on controlled-corruption protocols. It adds only 0.5--2.0k online parameters, with the slowest +MCC inference time at 0.089 ms/step. These results show that measurement semantics can turn process documents into lightweight pre-inference credibility correction and improve prediction accuracy.

Appliance-level energy monitoring in office buildings produces noisy alerts that non-expert facility managers struggle to use. This paper proposes an end-to-end agentic pipeline that combines deep time-series forecasting, variational anomaly detection, and LLM-based reasoning to generate prioritized, actionable maintenance recommendations. The system tracks seven office appliances using a hybrid Singular Spectrum Analysis (SSA) and Long Short-Term Memory (LSTM) forecasting model, and applies a per-appliance LSTM Variational Autoencoder (VAE) with attention to flag abnormal daily consumption episodes. A three-stage LangChain pipeline begins with a Context Agent that always retrieves three core RAG sources (model reliability, hourly baseline, and expert knowledge) and conditionally adds up to three more (forecast context, anomaly history, global baseline) based on event characteristics, capped at eight reasoning steps. A Diagnosis Agent converts the evidence into a structured JSON diagnosis, and a Report Agent renders a human-readable narrative. A reflective memory layer incorporates operator feedback. The dashboard shows real-time 30-minute forecasts, intraday consumption, the previous day anomaly report, and a feedback form. We evaluate the forecasting model, anomaly detector with appliance-specific thresholds, and LLM reasoning on a 16-scenario benchmark including sustained and transient spikes, unexpected shutdowns, and systemic events, comparing five LLM backends under static vs. dynamic retrieval. Dynamic retrieval matches full static retrieval across all backends while cutting average context from six to three-six sources per event. The best backend scores 90.4/100 with a 100% pass rate at a 70-point threshold, and a fully local 7B-parameter model passes all 16 scenarios.

Bearing fault diagnosis faces critical challenges when dataset heterogeneity, operating condition variations, and limited labeled data occur simultaneously in industrial environments. Existing approaches address these issues in isolation and rely on implicit feature alignment, limiting effectiveness under concurrent challenges. This paper proposes a knowledge-guided two-stage transfer learning framework that employs a lightweight GPT-2-style Transformer with causal self-attention for hierarchical feature extraction from vibration signals, establishing explicit pathways where pre-trained encoder weights and fault prototype embeddings serve as knowledge carriers from multi-source pre-training to target adaptation. The framework addresses the dual-shift challenge through multi-source learning for generalizable representations, prototype-based knowledge modulation for target adaptation, and taxonomy-adaptive classification for seamless transfer across heterogeneous fault categories. Experimental validation on four real-world datasets demonstrates 92.61% average accuracy with only 10% labeled target data, outperforming state-of-the-art methods by 17.24 percentage points, establishing a practical pathway toward cost-effective predictive maintenance in Industry 4.0 applications.

Accurate prediction of repair duration is an important challenge in product maintenance due to its implications for resource allocation, customer satisfaction, and operational performance. This study aims to develop a deep learning framework to help fleet repair shops accurately categorize repair time given product historical data. The study uses an automobile repair and maintenance dataset and creates an end-to-end predictive framework by employing a multi-head attention network designed for tabular data. The developed framework combines categorical information, transformed through embeddings and attention mechanisms, with numerical historical data to facilitate integration and learning from diverse data features. A weighted loss function is introduced to overcome class imbalance issues in large datasets. Moreover, an online learning strategy is used for continuous incremental model updates to maintain predictive accuracy in evolving operational environments. Our empirical findings demonstrate that the multi-head attention mechanism extracts meaningful interactions between vehicle identifiers and repair types compared to a feed-forward neural network and a random forest model. Also, combining historical maintenance data with an online learning strategy facilitates real-time adjustments to changing patterns and increases the model's predictive performance on new data. The model is tested on real-world repair data spanning 2013 to 2020 and achieves an accuracy of 78%, with attention weight analyses illustrating feature interactions.

Remaining useful life (RUL) estimation is central to predictive maintenance, where an unplanned failure can cost far more than the asset itself. Statistical degradation models miss the strong nonlinearity of real systems, and data-driven models often converge to suboptimal solutions in high-dimensional, non-convex search spaces. We propose a Quantum Annealing enhanced Q-Learning (QAQL) framework that couples the sampling behaviour of quantum annealing with the sequential decision making of Q-learning. Each Q-value update is encoded as a small quadratic unconstrained binary optimization (QUBO) whose ground state is the greedy action; rather than acting as a deterministic optimizer, the annealer returns a distribution over near-optimal actions across many reads, and this stochastic action selection supplies the exploration that curbs premature convergence on nonlinear degradation trajectories. The QUBO is solved on the D-Wave Advantage system using minor embedding, with the annealer woven into the reinforcement-learning loop rather than bolted on after training. We validate QAQL on two public benchmarks: the NASA C-MAPSS turbofan engine datasets and a device-fleet predictive maintenance dataset. Averaged over many independent runs and across six error metrics, QAQL outperforms the classical and quantum baselines considered in this study, with statistically significant improvements. The results indicate that quantum annealing is a usable, not merely theoretical, optimizer inside a reinforcement-learning loop for industrial predictive-maintenance applications.

Accurate state of health (SOH) estimation is a critical diagnostic service for lithium-ion battery management. However, reliance on labor-intensive manual feature engineering and opaque black-box models hinders scalable industrial deployment. To address this, we introduce TC-SOH: a modular, plug-and-play service architecture for autonomous, end-to-end SOH prediction. TC-SOH employs a temporal-contrastive mechanism and a cross-window prediction pretext task to extract degradation-relevant representations directly from raw operational data. To improve transparency, we connect model efficacy with representation diagnostics: visualization, sensitivity analysis, redundancy analysis, bidirectional probing, future-SOH probing, and temporal shuffling show that learned features overlap with selected expert descriptors while retaining additional SOH-relevant variation, and that ordered temporal context improves subsequent-SOH prediction. Across four public datasets, TC-SOH outperforms the considered physics-informed and data-driven baselines, reducing MAPE by 1.91 times and RMSE by 2.13 times.

Industrial retrofit planning depends on structured operational data rather than free text: planners must estimate whether a newly registered prototype will require a retrofit, which retrofit package it will need, and how long the work will take. We study an industrial dataset linking a prototype-registration system (284,271 vehicles) with a retrofit-management system (48,716 cleaned visits), and compare strong tabular machine learning baselines with three LLM-based strategies on row-serialized inputs: embedding features (Amazon Titan), direct prompted classification (Claude Sonnet 4), and an ML+LLM stacking approach. Across binary occurrence prediction, 15-way retrofit-type classification, per-visit duration regression, and an aggregated monthly benchmark, classical tree ensembles remain the strongest standalone models. However, the LLM results reveal a consistent pattern: embeddings remain useful on tables (binary AUC = 0.982), direct prompting collapses once semantic signal is stripped by hashing (binary AUC = 0.500; multiclass weighted F1 = 0.018), and hybrid stacking yields the best manually built multiclass model (weighted F1 = 0.626). On the monthly benchmark, lag-based machine learning outperforms time-series foundation models, though Chronos-small remains competitive in zero-shot forecasting. The results suggest that on privacy-constrained industrial tables, LLMs are more effective as complementary components than as replacements for strong tabular baselines.

Remaining Useful Life (RUL) prediction is essential for industrial predictive maintenance, yet many learning-based approaches rely on extensive feature engineering or large labeled datasets to train task-specific sequence models. In this work, we introduce a lightweight learning approach, in which we leverage a frozen pretrained time-series foundation model (TSFM) and combine it with a small regression head for RUL estimation from multivariate sensor streams. More specifically, we use Chronos-2 as a frozen backbone to extract context window features and train a lightweight regression neural network for RUL prediction. Experiments on real-world industrial sensor data from two device types show that Chronos-2 features consistently improve over recurrent, convolutional, Transformer-based, and gradient-boosting baselines under the same preprocessing and evaluation protocol. We further analyze the impact of context length and find that performance improves significantly with longer histories, indicating that TSFM representation offer a practical and data-efficient alternative for RUL estimation in industrial settings.

Condition-based Predictive Maintenance (PdM) for truck fleets has gained momentum in recent years. This maintenance strategy aims to minimize unplanned downtimes and reduce costs by monitoring the health status of vehicles and taking proactive action based on their condition. However, the implementation of condition-based PdM systems is challenging due to the large volume of data generated by the trucks, the inherent complexity of detecting failures through sensor data and the difficulties in finding cost-effective trade-offs in the solution's implementation. In this paper, we define and validate a condition-based PdM methodology built on the assumption that the wear-and-tear state of the monitored component can be represented as a monotonically non-decreasing time series. It involves selecting only the most recent observations from the time series and transforming them into a tabular format for classification using machine learning (ML) models designed for tabular data. Our results indicate that the proposed methodology reduces costs on the Scania Component X dataset compared to current state-of-the-art (SOTA) approaches, while also simplifying the modeling process through AutoML.

Predicting process-property relationships in manufacturing is often challenged by high experimental costs and the limited interpretability of complex 'black-box' models. This paper proposes a novel knowledge distillation framework designed to achieve high-accuracy predictions in data-scarce scenarios. The framework integrates analytical physics priors, which are systematically extracted from scientific literature via Large Language Models, into a privileged teacher model. We employ a Graph-Masked Attention layer to capture the complex physical dependencies among input variables showing strict setpoints or a combination of static and high-frequency temporal signatures. This privileged knowledge is distilled into a lightweight student predictor for inference. The feasibility and robustness of the framework are evaluated through a comprehensive experiment across five diverse manufacturing processes. To ensure statistical reliability, given the small dataset sizes, a repeated K-fold cross-validation technique is employed to quantify model stability and generalization. Results indicate that the proposed framework consistently achieves high predictive accuracy across all evaluated domains. Most importantly, the architecture demonstrates significant fault tolerance by maintaining robust predictive performance even in scenarios where LLM-derived analytical priors are suboptimal or incomplete. Furthermore, the student predictor achieves an inference frequency exceeding 6000 Hz, which facilitates real-time edge deployment on standard industrial hardware. This work provides a scalable solution for bridging the gap between theoretical physics and real-time industrial monitoring in data-limited environments.

Machine learning-based predictive emissions monitoring systems offer a practical alternative to direct emissions measurement, but their deployment across gas turbine fleets is challenging when emissions labels are available for only a small subset of assets. In this work, a trust-aware probabilistic framework is proposed for fleet-level gas turbine NOx prediction under limited labelled supervision. The framework combines a multi-head recurrent prediction model with learned confidence estimation, ensemble-based uncertainty quantification, auxiliary feature prediction, feature-space distance analysis, and operating-range diagnostics. These signals are calibrated on labelled data to produce interpretable per-sample trust scores, providing indicators of prediction reliability on unlabelled turbines, supporting the identification of predictions that should be treated with greater caution during fleet-level deployment. Confidence-based filtering reduces MAE from 0.202 at full coverage to 0.070 for the highest-confidence 10% of predictions, demonstrating that confidence estimates are meaningfully related to prediction error. Unlabelled and out-of-distribution samples exhibit increased uncertainty and reduced confidence, indicating that the framework responds appropriately to distributional shift. The results show that the proposed trust framework provides actionable reliability information for emissions prediction on unlabelled turbines, supporting more transparent and trustworthy deployment of PEMS across industrial fleets.

Data-driven Prognostics and Health Management (PHM) uses time-varying condition-monitoring data to diagnose system states and estimate remaining useful life in engineered assets. These tasks are central to maintenance planning, but industrial PHM data are often fragmented, partially observed, and poorly labeled, which hinders supervised learning. Foundation models offer a route toward reusable predictive systems, yet most time-series foundation models are designed for forecasting and assume long, coherent, regularly sampled sequences. To address this gap, we propose a framework for applying Tabular Foundation Models to industrial time series using in-context learning, and we evaluate them on a variety of PHM tasks. By converting raw unit-level signals into tabular rows, we show that these models perform well across multiple tasks - including prognostics, and diagnostics - and are highly data efficient. We compare them directly with sequence models, transformer baselines, and gradient-boosted trees under a common evaluation protocol. The results indicate that tabular foundation models achieve the best average ranks across prognostic and diagnostic tasks. Our findings further show that PFN-based models are competitive in low-data regimes, that temporal context can be preserved in the tabular representation, and that performance depends on representative context construction under subsampling. These results demonstrate that tabular foundation models provide a practical and general interface for heterogeneous PHM problems.

Returned products in circular factories re-enter production with heterogeneous degradation states, usage histories, and remaining capability. Reuse cannot be decided from the current inspection alone, because future function fulfillment and component integrity may evolve differently under the next service scenario. Existing PHM approaches support degradation prediction, but often target fixed operating conditions or isolated component benchmarks, while material-fatigue assessment is rarely linked to system-level functional prognosis. This paper addresses this gap for an angle grinder by combining uncertainty-aware functional prediction with component-level fatigue assessment in an instance-specific reliability workflow. The proposed framework combines the current tool state with recent force--torque usage windows. A convolutional encoder extracts loading patterns from spindle forces and shaft torque, and an LSTM backbone predicts nine functional variables as Gaussian mean and variance estimates. In parallel, the same loading history is translated into output-shaft fatigue information through finite-element-supported stress reconstruction, S--N/Miner damage evaluation with Haibach extension, and Paris-law crack-growth analysis. A streaming replay algorithm consolidates both branches into functional, material, and system reliability trajectories. Held-out tests show mean $2\%$-tolerance accuracy of 0.9652 across nine outputs. Thermal variables are predicted near-perfectly, while drive motor current and load speed remain the most demanding dynamic outputs, with $R^2$ values of 0.9750 and 0.9924. Torque history is especially important for these variables, and the conventional LSTM outperforms GRU and xLSTM in the short-history setting. Reliability calibration is most informative for drive motor current, where predicted and observed exceedance probabilities ...

Accurate Remaining Useful Life prediction is critical for industrial predictive maintenance. However, real-world deployment is challenging due to the irregular nature of sensor observations, characterized by asynchronous sampling, burst missingness, and temporal jitter. Compounding this issue, purely data-driven models often generate physically implausible degradation trajectories that violate the irreversible nature of damage accumulation. To address this, we propose PC-MambaSDE, a unified continuous-time framework for robust RUL prediction under irregular observations. Specifically, we design a Mask-Aware Continuous Mamba Encoder that explicitly leverages observation masks to extract context-rich control signals. Furthermore, we introduce a Physics-Guided Latent SDE with parametrically rectified hybrid drift, superimposing a global physical bias to enforce monotonic degradation even amid severe observation gaps. Additionally, we formulate RUL prediction as a boundary value problem via a Terminal Degradation Penalty, which decouples a Health Index dimension and applies a penalty loss to guide trajectories toward the failure state. Theoretically, we prove that our variational objective is mathematically equivalent to minimizing the KL divergence via Girsanov's theorem, and we guarantee the global asymptotic stability of the learned dynamics through Lyapunov analysis. To enable rigorous evaluation, we develop a Hybrid Irregularity Generation Scheme that simulates realistic industrial imperfections. Extensive experiments on public benchmarks demonstrate that PC-MambaSDE significantly outperforms state-of-the-art methods, particularly under extreme observation scarcity, validating the efficacy of embedding physical priors into continuous-time latent dynamics.

As wind turbine fleets age, data-driven reliability engineering is essential to optimise their operation and maintenance for service life extension and levelised cost of energy reduction. Failure event descriptions within historical maintenance logs are a source of valuable reliability intelligence. However, they typically appear as unstructured natural language entries, rendering them inaccessible for quantitative analysis. This paper presents a novel methodology leveraging a large language model (LLM) to systematically standardise and structure maintenance logs based on their free-text descriptors. Operating on a dataset of 16,316 maintenance logs from 280 turbines monitored over nine years, the developed model-agnostic framework autonomously corrected hierarchical system codes and extracted evidence-based taxonomies of maintenance actions and failure modes. The automated pipeline successfully structured over 70% of the dataset. It resolved pervasive misclassification issues, such as isolating previously unclassified pitch system faults and restoring missing system codes, and enriched the records by applying empirical taxonomies to label specific actions taken and failure modes addressed. By using system-based log batches to construct empirical dictionaries of failure modes, observable symptoms, dominant mechanisms, and candidate causes, this approach reduces the inherent subjectivity of manual failure modes and effects analysis (FMEA). Ultimately, the methodology provides a highly scalable, cost-effective blueprint for translating large sets of qualitative field observations into quantitative reliability metrics, laying the foundation for integrated root-cause analysis across the renewable energy sector, improved FMEA, and advanced predictive maintenance.

Engine Health Management (EHM) depends on reliable forecasting of Remaining Useful Life (RUL) and on tracking thermal indicators such as turbine gas temperature (TGT). In practice, real-world fleet data are heterogeneous and non-stationary, and point predictions alone are insufficient for risk-aware maintenance decisions. This paper presents a multi-task scientific machine learning framework for turbine prognostics that jointly predicts turbine gas temperature untrimmed (TGTU), Delta Turbine Gas Temperature (DTGT), and RUL, with quantified uncertainty in the form of prediction intervals whose empirical coverage is evaluated. A shared sequence encoder (convolutional front-end with residual bidirectional LSTM layers and attention pooling) feeds task-specific heads, including mean--variance estimation for probabilistic regression and, optionally, a survival head for threshold-based event modeling. The framework is designed to be tunable via a small set of practitioner-facing parameters (e.g., DTGT thresholding rules and RUL target construction) so that deployment can align with in-house policies and proprietary criteria. The predictive performance of the proposed framework is evaluated using both point and interval metrics, including mean absolute error (MAE), prediction interval coverage probability (PICP), mean prediction interval width (MPIW), and the coverage--width criterion (CWC). Results are reported both in aggregate and stratified by flight phase and maintenance segment to highlight operational-context effects and to support uncertainty-aware monitoring.

Industrial Prognostics and Health Management (PHM) provides a representative case study for a broader challenge in applied machine learning: translating published papers into executable, benchmark-ready implementations. Reproducing under-specified methods in PHM is particularly difficult due to restricted access to industrial datasets, incomplete reporting of preprocessing and evaluation protocols, and implicit design choices (e.g., windowing, target construction, data splits) that critically affect performance. Existing paper-to-code systems generate implementations for individual papers, but these artifacts are often not directly comparable due to inconsistencies in assumptions and evaluation settings. We introduce \emph{agentic, framework-based PHM paper reproduction}, where an agent translates a paper into a shared PHM benchmark framework via a \emph{slot-binding interface}. This interface maps equations and protocol descriptions into structured components (task definitions, dataset adapters, windowing, targets, models, and evaluators), while explicitly recording unresolved assumptions. The resulting implementations are validated against standardized task contracts and evaluation hooks, enabling consistent and comparable benchmarking. We evaluate this approach on 16 PHM papers, comparing framework-enhanced, skill-based and prompt-based agentic reproduction against a recent framework-free paper-reproduction agent. We assess reproduction success, model-based code evaluation, framework binding of paper assumptions, and cross-paper benchmark comparability under standardized protocols. Our results show that coupling agentic generation with a shared framework transforms paper reproduction from isolated code synthesis into executable, assumption-aware, and systematically comparable benchmark implementations.

Infrastructure deterioration poses significant challenges for asset management, yet existing approaches rely on population-averaged models that overlook equipment-specific heterogeneity. We present a novel framework that combines Bayesian hierarchical hazard modeling with causal discovery to identify operational patterns that drive heterogeneous deterioration rates in pump equipment. Our approach first estimates pump-specific random effects $u_i$ using GPU-accelerated No-U-Turn Sampling (NUTS), achieving 3--5$\times$ speedup over CPU implementations. We then employ DirectLiNGAM to discover causal relationships between 22 engineered time-series features and deterioration rates, stratified by positive ($u_i > 0$, faster deterioration) versus negative ($u_i \leq 0$, slower deterioration) random effects. Analyzing 112 pumps with 92,861 observations over 650 days, we uncover striking heterogeneity: the negative group exhibits causal effects 400$\times$ larger than the positive group, with standard deviation (std) showing a strong positive causal effect ($+1.515$) on deterioration rates in low-risk equipment. We validate linearity assumptions through NonlinearLiNGAM comparison and demonstrate practical scalability through GPU acceleration. Our findings enable targeted maintenance strategies by revealing that different operational regimes require fundamentally distinct management approaches, advancing predictive maintenance from population-averaged to heterogeneity-aware decision making.

Predictive maintenance in complex systems is often complicated by the heterogeneity and redundancy of monitored variables,which can obscure fault-relevant information and reduce model interpretability. This work proposes a semantic feature segmentation framework that decomposes the monitored feature space into a canonical component,expected to retain the dominant predictive information, and a residual component containing structurally peripheral signals. The segmentation is defined through domain informed criteria and sets up monitoring variables into functional groups reflecting operational mechanisms such as throughput,latency,pressure,network activity,and structural state. To evaluate the effectiveness of this decomposition, we adopt a predictive perspective in which expected predictive risk is used as an operational proxy for task-relevant information. Experimental results obtained through time-aware cross-validation show that the canonical space consistently achieves lower predictive risk than the residual space across multiple temporal configurations, indicating that the semantic segmentation concentrates the most relevant information for fault anticipation. In addition, the canonical segments exhibit significantly stronger intra-segment coherence than inter-segment dependence, and this structural organization remains stable after redundancy reduction. When compared with the full feature space and with a Principal Component Analysis (PCA) representation, the canonical space carries out comparable predictive performance and furthermore preserves the semantic meaning of the original variables. These findings suggest that semantic feature segmentation provides an interpretable and information-preserving decomposition of monitoring signals, enabling competitive predictive performance without sacrificing the operational interpretability required in predictive maintenance applications.

Federated Learning (FL) has emerged as a promising paradigm for preserving client data ownership and control over distributed Internet of Things (IoT) environments. While discriminative models dominate most FL use cases, recent advances in generative models -- such as Variational Autoencoders (VAE), Generative Adversarial Networks (GAN), and Diffusion Models (DM) -- offer new opportunities for unsupervised anomaly detection in time series analysis, with relevant applications in predictive maintenance (PdM) in critical industrial infrastructures. In this work, we present a comprehensive analysis of VAEs, GANs, and DMs in the context of federated PdM. We analyze their performance and communication overhead under both full and partial federation setups, where only subsets of model components are shared. Building on this analysis, the paper proposes a novel taxonomy for federated generative models that formalizes partial component sharing as a principled mechanism for model personalization. Our experiments over a real-world time series dataset reveal distinct trade-offs in model utility, stability, and scalability, especially in heterogeneous and bandwidth-constrained FL settings. For the evaluated GAN-based configurations, full federation improves training stability relative to independent local training, although the model remains less robust than the VAE- and DDPM-based alternatives. For DMs, however, partial federation -- especially decoder sharing -- can outperform full federation in bandwidth-constrained, non-IID settings.

Accurate prediction of Remaining Useful Life (RUL) in aero-engines is vital for predictive maintenance, improved operational reliability, and reduced lifecycle costs. While deep learning approaches have demonstrated strong potential in this area, most existing methods focus primarily on model architecture design and treat input features uniformly, often neglecting the influence of data preprocessing. In this work, we propose a novel preprocessing pipeline that enhances RUL prediction by improving data quality and temporal representation before model training. Our approach leverages complete temporal sequences and generates RUL estimates at each timestep, enabling the model to capture fine-grained degradation dynamics and deliver continuous prognostic insights throughout the engine's operational life. To validate the effectiveness of the proposed pipeline, we conduct experiments on the NASA C-MAPSS dataset. Comparative evaluations against a suite of state-of-the-art neural models including CNN, RNN, LSTM, DCNN, TCN, BiGRU-TSAM, AGCNN, and ATCN, demonstrate that our approach consistently achieves superior accuracy and robustness in aero-engine RUL prediction. These results highlight the critical role of preprocessing in maximizing the effectiveness of neural prognostic models.

Accurate forecasting of battery health indicators, including remaining capacity and lifetime, is of paramount importance for ensuring the reliability, safety, and operational efficiency of applications such as electric vehicles and large scale energy storage infrastructures. The result of the forecasting can be adopted to build an advanced monitoring mechanism for continuous checking batteries' health status to assist in the efficient real-time management of numerous applications. This research investigates the development and implementation of a Deep Learning (DL) model for the prediction of the future state and performance of industrial electrochemical energy storage systems. To address this challenge, we propose a dedicated computational framework that integrates advanced neural network architectures with large-scale training datasets, enabling precise modeling of batteries degradation dynamics and operational trends. The proposed approach provides a decision support mechanism for the optimal management of batteries facilitating both predictive maintenance and the efficient allocation of energy resources. Our findings highlight the potential of DL-based predictive modeling to significantly contribute to the advancement of sustainable and intelligent energy management systems.

Federated prognostics enable clients (e.g., companies, factories, and production lines) to collaboratively develop a failure time prediction model while keeping each client's data local and confidential. However, traditional federated models often assume homogeneity in the degradation processes across clients, an assumption that may not hold in many industrial settings. To overcome this, this paper proposes a personalized federated prognostic model designed to accommodate clients with heterogeneous degradation processes, allowing them to build tailored prognostic models. The prognostic model iteratively facilitates the underlying pairwise collaborations between clients with similar degradation patterns, which enhances the performance of personalized federated learning. To estimate parameters jointly using decentralized datasets, we develop a federated parameter estimation algorithm based on proximal gradient descent. The proposed approach addresses the limitations of existing federated prognostic models by simultaneously achieving model personalization, preserving data privacy, and providing comprehensive failure time distributions. The superiority of the proposed model is validated through extensive simulation studies and a case study using the turbofan engine degradation dataset from the NASA repository.

Predictive maintenance for connected vehicles offers the potential to reduce unexpected breakdowns and improve fleet reliability, but most existing systems rely exclusively on internal diagnostic signals and are validated on simulated or industrial benchmark data. This paper presents a contextual data fusion framework integrating vehicle-internal sensor streams with external environmental signals -- road quality, weather, traffic density, and driver behaviour -- acquired via V2X communication and third-party APIs, with inference at the vehicle edge. The framework is evaluated across four layers. A feature group ablation study on a physics-informed synthetic dataset shows contextual features contribute a 2.6-point F1 improvement; removing all context reduces macro F1 from 0.855 to 0.807. On the AI4I 2020 benchmark (10,000 samples), LightGBM achieves AUC-ROC 0.973 under 5-fold stratified cross-validation with SMOTE confined to training folds. A noise sensitivity analysis shows macro F1 remains above 0.88 at low noise and degrades to 0.74 at high noise. Most critically, the pipeline is validated on real-world telemetry from five vehicles across three countries (India, Germany, Brazil), comprising 992 trips and 11 evaluable service events identified from component wear resets in the trip logs. Across six wear-driven events spanning four vehicles, the model achieves 100% detection with mean MAE of 12.2 days. A fine-tuning ablation shows the base synthetic model already achieves 6/6 binary detection; per-vehicle adaptation reduces wear-driven MAE from 25.9 to 12.2 days. SHAP analysis confirms contextual and interaction features rank among the top 15 predictors. Edge-based inference reduces estimated latency from 3.5 seconds to under 1.0 second relative to cloud-only processing.

Dominant approaches for modelling Partial Differential Equations (PDEs) rely on deterministic predictions, yet many physical systems of interest are inherently chaotic and uncertain. While training probabilistic models from scratch is possible, it is computationally expensive and fails to leverage the significant resources already invested in high-performing deterministic backbones. In this work, we adopt a training-efficient strategy to transform pre-trained deterministic models into probabilistic ones via retrofitting with a proper scoring rule: the Continuous Ranked Probability Score (CRPS). Crucially, this approach is architecture-agnostic: it applies the same adaptation mechanism across distinct model backbones with minimal code modifications. The method proves highly effective across different scales of pre-training: for models trained on single dynamical systems, we achieve 20-54% reductions in rollout CRPS and up to 30% improvements in variance-normalised RMSE (VRMSE) relative to compute-matched deterministic fine-tuning. We further validate our approach on a PDE foundation model, trained on multiple systems and retrofitted on the dataset of interest, to show that our probabilistic adaptation yields an improvement of up to 40% in CRPS and up to 15% in VRMSE compared to deterministic fine-tuning. Validated across diverse architectures and dynamics, our results show that probabilistic PDE modelling need not require retraining from scratch, but can be unlocked from existing deterministic backbones with modest additional training cost.