GermanyChemicals and materials2025 – ongoingLANXESS
AI-based predictive maintenance for critical plant machinery
LANXESS reported seven-figure savings from AI that flags machine faults hours to weeks ahead, and is extending it to more plants
Problem
Unplanned failures of pumps, compressors and other critical machines interrupt chemical production and cost money.
Approach
A central team in Leverkusen, the Production, Technology, Safety and Environment unit, monitors critical machines at plants worldwide. Sensors feed AI models that compare vibration and temperature profiles and other process variables with normal behavior and flag deviations. Head of Predictive Maintenance Bastian Hoefer leads the global rollout, which the company says will take months more for other systems and machines.
Results
Takeaway
LANXESS uses a central team to monitor machines across plants and plans to extend AI to whole production processes. It reports only a seven-figure savings range, without an exact amount or the number of plants and machines covered.
Categories
- Size
- Large enterprise
- Industry
- Chemicals and materials
- Business function
- Production and quality
- Innovation type
- Process innovation
- AI technology
- Predictive analytics and ML
- Adoption
- Built in-house
- Evidence
- Company's own claim
Sources
Source summaries
LANXESS describes a Leverkusen team that uses sensor data and AI models to watch critical machines in plants worldwide. It says failures can be spotted hours, days and sometimes weeks ahead and that savings are in the seven-figure range. Rollout to further systems will take months.
Full details are in the original sources.
