Transforming Predictive Maintenance Through Physics: How AccuPredict Is Driving Innovation and a Paradigm Shift in Manufacturing
Unexpected machinery downtime is a critical challenge for manufacturers, directly resulting in lost productivity and increased costs. In recent years, predictive maintenance powered by artificial intelligence and machine learning has attracted considerable attention as a potential solution. However, conventional approaches often require months of historical data before they can generate meaningful insights, while identifying the root cause of a failure remains difficult.
Against this backdrop, Singapore-based startup AccuPredict is bringing innovation to predictive maintenance through a unique approach that combines AI with physics. Over the past five years, the company has maintained a 100% customer retention rate. Its solutions have been highly regarded by customers, particularly Fortune 500 companies in the United States, and AccuPredict is now accelerating its global expansion.
We spoke with Milind Yedkar, Co-founder and CEO of AccuPredict, who has 38 years of business experience across India, Japan, China, and Singapore, about the company’s groundbreaking technology and vision.
"Machines Run Forever": A Physics-Based Approach
Our mission is very simple: “Machines run forever.” We firmly believe that a properly designed machine should not experience unexpected shutdowns.
Most predictive maintenance solutions available today rely on AI- and machine learning-based pattern matching. These systems essentially say, “A component failed the last time this vibration pattern appeared, so you should replace the component.” However, they do not explain why the component is failing in the first place.
AccuPredict takes a different approach. We begin with physics and combine it with AI. Our algorithms can accurately identify the underlying causes of machinery failure, including insufficient or excessive lubrication, misalignment, imbalance, and foundation-related issues. By identifying and addressing the root cause, customers can prevent the same problem from recurring. This ability to eliminate the cause of failure, rather than merely detecting a correlated pattern, is the key difference between AccuPredict and its competitors around the world.
Four Poweful Advantages: No Historical Data Required and 97% Accuracy
The technical benefits we provide to customers can be summarized in four key advantages.
1. Identifying Root Causes, Not Correlations
Rather than simply identifying correlations between patterns and failures, our solution determines the specific cause of a problem. This enables customers to address the issue at its source and achieve a fundamental, long-term resolution.
2. No Historical Data Required
Unlike machine learning systems, our solution does not require three to six months of accumulated data before analysis can begin. In the same way that a doctor can examine an X-ray and immediately determine whether a bone is fractured, our engineers can measure vibration at critical points on a machine for just one minute and immediately identify where an abnormality is occurring.
3. Warnings up to 100 Days in Advance
Instead of notifying customers only a few days before a problem occurs, our system can issue warnings up to 100 days in advance. This not only helps prevent machine failure but also enables manufacturers to extend the service life of their components.
4. Extremely High Predictive Accuracy
Our predictions are not affected by the false positives and false negatives commonly associated with AI-based systems.
The principle is similar to that of a spectroscope, which can accurately identify the composition of a material by analyzing the light passing through it. Because our solution is based on physical properties, the algorithm can accurately identify the actual problem.
Case Study: Dramatic Cost Savings by Eliminating Routine Maintenance
AccuPredict’s solution can be applied to virtually any type of machinery across a wide range of industries, including consumer goods, beverages, pharmaceuticals, automotive manufacturing, power generation, and oil and gas.
In one case involving a consumer goods manufacturer, we installed 25 sensors on two machines that were particularly prone to failure.
During the three-month pilot program, the customer suspended its regular maintenance activities, including manufacturer-recommended component replacements. Instead, it carried out only the actions recommended by AccuPredict.
As a result, machine failures decreased immediately. The customer also achieved significant reductions in repair time, spare-parts consumption, and employee overtime. The project is now moving into the global deployment phase across the customer’s operations.
In a separate collaboration with an automotive company, we developed a compact onboard algorithm that uses acoustic sensors to identify the causes of abnormal driving noises without requiring an internet connection. This technology is helping improve the productivity of automotive repair and service centers.
Our physics-based approach is also being applied in the mining industry to solve a variety of challenges, including detecting pipeline blockages and predicting pipe ruptures caused by wall-thickness reduction.
We also offer an unconditional, full money-back guarantee if our solution fails to achieve the agreed machinery reliability improvement targets during the 90-day pilot period.
We are able to offer this guarantee because we have absolute confidence that physics does not fail.
A Simple Dashboard and Hands-On Customer Support
Our system is designed to minimize the workload placed on personnel at manufacturing sites. The dashboard provided each day is extremely straightforward, displaying intuitive instructions such as: “Clean the blower.” “Plan balancing work.”
These are actions that can be easily carried out by a technician with four to five years of experience.
The system can also identify multiple issues in a single notification, reducing the need to shut down the same machine repeatedly.
To support our customers, our onsite and offsite teams work closely together through a 30-minute meeting held once a week. In urgent situations, we can communicate immediately through messaging applications such as LINE and WhatsApp. By maintaining close, continuous communication with our customers, we work alongside them to optimize their machinery and operations.
Sustainability is another important benefit of our solution. For example, if installation-related problems are corrected and machine vibration is reduced from 15 mm/s to 4 mm/s, unnecessary energy losses caused by vibration can be eliminated. As a result, customers can reliably reduce machinery energy consumption by approximately 10% to 30%.
Entering the Japanese Market and Strengthening the Competitiveness of Japanese Manufactures
Our goal is to support Japanese manufacturers in strengthening their global competitiveness once again. To achieve this, we plan to establish a presence in Japan and recruit local engineers and technical specialists by the end of 2026. Although several competing solutions are already available in Japan, AccuPredict offers clear advantages. Some AI- and machine learning-based services depend heavily on historical patterns. Meanwhile, solutions developed by spin-offs from major corporations that use acoustic noise sensors tend to be extremely expensive to implement. Their configurations are complex, and considerable support is often required before the systems can become fully operational. Oil-testing methods have another limitation. They detect particles only after damage has already occurred and cannot determine exactly where the damage is taking place or what caused it. AccuPredict’s approach is fundamentally different. By applying physics, we identify the root cause before serious damage occurs.
We are also steadily building a track record in Japan. We have already formed a partnership with a company in Nagoya. In one project involving a large compressor at the Port of Nagoya, we accurately identified the problem after just a single measurement. The maintenance personnel at the site were highly impressed by the accuracy of our diagnosis. We are also working with a power-generation company to identify the causes of problems such as blockages affecting water gates.
Japanese companies working with AccuPredict will receive a clear, fully localized Japanese-language dashboard. They will also be able to communicate directly with engineers in Japan during Japan Standard Time. Customers will not have to worry about needing to speak with someone in Singapore. We intend to work as a long-term local partner for Japanese manufacturers, supporting them in improving machinery reliability. We look forward to collaborating with companies across Japan.
■Conclusion
By combining advanced physics with AI, AccuPredict’s predictive maintenance solution has the potential not only to eliminate one of manufacturing’s most persistent challenges; unexpected downtime but also to dramatically reduce maintenance workloads and lower energy consumption by 10% to 30%. The technology requires no historical data, can identify root causes from the first day of implementation, and eliminates the false alarms that represent a major weakness of conventional AI-based solutions.
AccuPredict’s approach has the potential to create a paradigm shift in industrial operations across a wide range of sectors. With preparations underway to establish a Japanese entity by the end of 2026, expectations are growing that AccuPredict will become a powerful partner in strengthening the competitiveness of Japan’s manufacturing industry.
Interviewed Company Overview
Company name: AccuPredict Services Pte Ltd
Website: https://accupredict.io/
For inquiries regarding collaboration or business discussions with the interviewee company, please contact either Third Ecosystem, inc., the operator of this media platform, or the interviewee company directly.
