Three months ago, a plant manager at a 400 MW combined-cycle facility was still manually cross-referencing DCS alarms against a shift log to decide whether to ramp down a gas turbine. Today, that same manager watches iFactory overlay real-time vibration and temperature data onto a digital twin of the unit, flag a bearing degradation pattern 72 hours before any threshold is breached, and automatically adjust the load schedule to keep the plant online. The unplanned outage that used to cost $180,000 per event simply stopped happening. That is the difference between reacting to breakdowns and letting operations run themselves.
From 180K outage losses to zero — iFactory gives your plant team the power to see failures before they happen
iFactory's on-premise, turnkey AI platform ingests your plant's DCS, CMMS, and sensor data, then delivers a working pilot in 6–12 weeks that predicts equipment degradation and prescribes load adjustments — no cloud, no data egress, no IT project drag.
Your plant's new normal: four metrics that prove the shift
These are not projections. They are the operational baseline iFactory delivers within one quarter of deployment — measured against your plant's own historical data.
Four capabilities that turn sensor noise into dispatch decisions
iFactory is not a dashboard. It is an operational layer that sits on your plant network, fuses every data source you already own, and outputs prescriptive actions your control room can execute immediately.
Digital Twin of Every Rotating Asset
iFactory builds a physics-informed model of each gas turbine, steam turbine, pump, and fan. The twin ingests live vibration, temperature, pressure, and flow data at 1 Hz and flags any deviation from normal operating envelope — not a fixed threshold, but a dynamic baseline that learns as the unit ages.
Prescriptive Load Scheduling
When a bearing degradation pattern is detected, iFactory does not just send an alert. It calculates the maximum safe load the unit can carry for the next 96 hours, then suggests a revised dispatch curve that keeps the unit online until the next planned maintenance window. The control room sees one instruction: "Reduce load to 340 MW by 14:00."
Root-Cause Forensics in One Click
When an anomaly is flagged, iFactory traces the signal path back to the originating sensor and the operating condition that triggered the drift. Your reliability engineers get a full timeline — not a red light and a work order, but a narrative: "High vibration on HP turbine bearing #2 began 47 hours ago, correlated with a 12 °C rise in lube oil temperature and a 3% throttle valve position change."
Automated CMMS Work Order Creation
iFactory writes the work order directly into your existing CMMS — SAP, Maximo, or Infor — with the predicted failure mode, the recommended repair action, and the optimal window for execution. No data entry. No manual handoff from the DCS to the planner.
The cost of running blind is measured in megawatts and margin
Every plant has the data. Most lack the operational intelligence to use it. Here is what happens when you do not have iFactory connecting the dots.
Outage costs that compound
A single unplanned trip on a 400 MW gas turbine costs $180,000 in lost generation revenue, replacement power costs, and emergency labor. If that turbine trips four times a year, that is $720,000 gone — money that could have been avoided with a 96-hour prediction.
Maintenance that reacts instead of plans
Without predictive insight, your team is always in firefighting mode. Overtime labor runs 30–40% higher than planned. Parts are expedited at premium freight rates. The maintenance budget becomes a cost center instead of a reliability investment.
Heat rate drift that erodes margin
When equipment operates outside its optimal envelope — even by a few degrees or a few psi — heat rate climbs. A 1.8% degradation in heat rate on a 400 MW unit burning natural gas at $3.50/MMBtu adds over $400,000 in annual fuel cost. That is margin you are leaving on the table.
Your plant already has the sensors, the historians, and the CMMS. What it does not have is the layer that turns that data into a decision. Book a 30-min walkthrough and see how iFactory connects them in 6–12 weeks.
Four steps from data-source access to operational intelligence
iFactory is end-to-end and turnkey. You hand over access to your DCS, CMMS, and sensor historians. We deliver a working pilot in 6–12 weeks. No cloud, no data egress, no IT project drag.
Connect
iFactory's on-premise appliance connects directly to your plant network — OPC-UA, Modbus, PI, or OSIsoft — and ingests 12+ months of historical data alongside live streams.
Model
Our AI builds a digital twin of every critical asset: gas turbines, steam turbines, pumps, fans, and heat exchangers. The model learns normal operating envelopes for each unit.
Predict
iFactory continuously compares live sensor data against the digital twin. When a deviation pattern emerges — vibration drift, temperature creep, pressure drop — it predicts the remaining useful life with 96-hour lead time.
Prescribe
The platform outputs a specific operational instruction: a revised load schedule, a maintenance window, or an automated work order. Your control room executes. The outage never happens.
Four promises that define the iFactory delivery
This is not a SaaS subscription that leaves you guessing about data security or deployment timelines. This is a complete operational capability, delivered on your network, in one quarter.
End-to-end, turnkey delivery
You provide data-source access. iFactory handles the rest — data ingestion, model building, validation, and deployment. A working pilot in 6–12 weeks, not 6–12 months.
On-premise, zero cloud dependency
iFactory runs on an NVIDIA appliance inside your plant network. No data leaves your firewall. No cloud subscription. No third-party data center. Your operational data stays yours.
Pilot-to-ROI in one quarter
We measure success by the metrics that matter to your P&L: unplanned outage reduction, maintenance cost saved, and heat rate improvement. ROI is demonstrated within 12 weeks of go-live.
24x7 managed service
iFactory includes continuous model monitoring, retraining, and support. Your team gets the intelligence. Our team keeps the engine running. No additional headcount required.
Questions plant operators actually ask about predictive operations
Stop reacting to outages before they cost you another $180,000
iFactory gives your plant the predictive intelligence to see failures 96 hours in advance and the prescriptive capability to keep the unit online. Book a 30-minute walkthrough and we will show you a live demo on power generation data.
