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From Breakdowns to Breakthroughs: Predictive
Maintenance with IoT and SAP

How Datafy Inc. Helped a Manufacturing Giant Automate Maintenance Before Machines Fail

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30% reduction

in unplanned machine downtime

22% decrease

in annual maintenance costs

3x faster

maintenance order generation and execution

The Challenge: Costly Downtime and Inefficient Maintenance Planning

A large industrial manufacturer faced frequent unplanned equipment failures, resulting in production delays, expensive emergency repairs, and operational inefficiencies. Their existing reactive maintenance model couldn’t keep up with increasing machine complexity and production demands.

Despite installing IoT sensors to collect real-time data on temperature, vibration, and pressure, the company lacked integration with SAP ERP to act on this data intelligently.

The Solution: SAP-Powered Predictive Maintenance Engine by Datafy Inc.

Datafy Inc. implemented a solution that connected IoT sensor platforms with SAP’s Plant Maintenance (PM) module using BAPIs to automate predictive maintenance workflows.

Key actions included:

Importing real-time sensor data into SAP for centralized monitoring
Automatically triggering maintenance orders when abnormal conditions were detected
Enabling data-driven analysis and predictive modeling for long-term insights

The Results:
Downtime Eliminated; Uptime Maximized

The integrated solution transformed the client’s maintenance strategy:

  • Maintenance tasks were triggered before failures occurred.
  • Equipment uptime improved, while costly emergency repairs
    dropped significantly.
  • SAP became a central hub for real-time equipment health monitoring and proactive maintenance planning.

Download the full case study