Predictive reliability for the automotive line
Robotic arms, conveyors, stamping presses, and welding cells operate at takt times measured in seconds. A single bearing failure on the main line can stop the whole plant. Haltless monitors vibration, current, and thermal signatures on every critical asset so you intervene before takt-time slips.
EQUIPMENT WE MONITOR
Four asset families that ship with day-one connector support. No proprietary sensors, no custom integration sprint.
Six-axis articulated arms on body-in-white lines, tracked through joint current, motor temperature, and cycle-time signatures.
Mechanical and hydraulic presses for hoods, doors, and structural panels, monitored on cylinder pressure, ram velocity, and bearing vibration.
Skid conveyors, oscillating spray applicators, and dip tanks tracked for chain tension, motor draw, and tank temperature.
Servo torque tools, screw stations, and pallet shuttles read over OPC UA for the immediate context behind every cycle-time miss.
FAILURE MODES WE CATCH
Three deterministic detectors run in parallel against every reading. These are the failure modes they tend to flag early in this industry.
Velocity drift in spindle and ram bearings flagged days before catastrophic seizure.
Slow leaks in cylinders and accumulators identified through rate-of-change on supply pressure.
Z-score on torque-tool and conveyor motor current catches winding faults hours before the line trip.
INDUSTRY CONTEXT
Tier-1 automotive plants run at takt times measured in seconds, with line OEE targets above 85 percent. A single weld-cell stoppage on the main line is six-figure exposure within the hour, and IATF 16949 traceability means every action has to be reproducible. Haltless gives the maintenance lead an explainable health score on every critical asset and a tamper-evident audit log of every alert, work order, and signoff.
Vibration, thermal, and current signatures flagged before they cascade into a stoppage.
A 40MB Python agent runs on any Linux box next to your existing PLCs. No new sensors required.
Open APIs and pre-built connectors for SAP, Maximo, ServiceNow, and Jira route alerts straight into work orders.
Connect Haltless to your existing PLCs, run a pilot on up to ten machines, and see the explainable health score on your own equipment. No new hardware, no proprietary sensors, no consultants.
