M08-04 · AI + Robotics & Automation Operations

Predictive Maintenance and Hardware Diagnostics

AI + Robotics & Automation Operations →

Teaches students to maintain robot fleet reliability through predictive, preventive, and reactive maintenance strategies. Covers sensor data interpretation (motor current signatures, vibration patterns, temperature trends, cycle time drift), AI-assisted anomaly detection, remote diagnostics workflows, hardware diagnostic decision trees, spare parts inventory management (MTBF analysis, lead times), and the data discipline of logging every repair to build the maintenance intelligence that turns reactive operations into predictive operations.

30 Hours
8 Learning objectives
Evaluate Bloom's ceiling (?)
5 Competencies

Learning Objectives

Objectives

Depth
  • Analyze sensor data streams — motor current, vibration, temperature, and cycle time — to identify early indicators of component degradation before failure occurs Analyze
  • Evaluate AI-assisted anomaly detection alerts (e.g., "left drive motor current 15% above baseline, predicted bearing failure in 7-14 days") to prioritize maintenance scheduling during low-volume windows Evaluate
  • Apply remote diagnostic workflows — pulling navigation logs, LIDAR data, network logs, and software version data — to resolve 60% of reported issues without dispatching a field visit Apply
  • Create hardware diagnostic decision trees organized by symptom ("robot stops unexpectedly" → check battery → check network → check obstacle detection → check software version → escalate) Create
  • Analyze MTBF (Mean Time Between Failure) data per component type to optimize preventive maintenance schedules — replacing components at data-driven intervals rather than fixed calendar schedules Analyze
  • Apply a spare parts inventory strategy based on component failure rates, lead times, and regional depot placement to reduce MTTR (Mean Time To Repair) Apply
  • Create comprehensive maintenance logs in a CMMS capturing robot ID, failure mode, root cause, parts replaced, labor hours, and downtime duration to build the dataset that enables predictive maintenance Create
  • Evaluate the cost tradeoff between reactive (fix when broken), preventive (fixed schedule), and predictive (data-driven) maintenance approaches for different component types Evaluate

Levels: Remember · Understand · Apply · Analyze · Evaluate · Create — highest demands most original thinking.

What You'll Master

Sensor Data Interpretation

Reading motor current signatures, vibration spectra, temperature trends, and cycle time drift to diagnose component health; understanding what "normal" looks like for each sensor type so deviations are recognized immediately.

Predictive Maintenance Program

Using AI-assisted analytics to predict failures, scheduling maintenance during low-impact windows, transitioning from reactive/preventive to data-driven predictive operations.

Remote Diagnostics

Systematically investigating reported issues using remote telemetry (logs, sensor data, network status, software version) before dispatching field visits; resolving the majority of issues without on-site presence.

Spare Parts & Inventory Management

Tracking MTBF per component, managing regional spare parts depots, optimizing inventory levels based on failure rates and lead times, reducing MTTR through strategic stocking.

Maintenance Data Discipline

Logging every repair comprehensively in a CMMS, building the dataset that reveals failure patterns over 6+ months, adjusting maintenance schedules based on accumulated operational evidence.

What You'll Build

Predictive Maintenance Program Design — Student receives 6 months of fleet telemetry data for 30 robots. They produce: a sensor data analysis identifying 5 components trending toward failure with predicted timelines, a preventive maintenance schedule optimized from MTBF data (comparing current fixed schedule vs. data-driven recommendation), a spare parts inventory plan with stocking levels justified by failure rates and lead times, 3 hardware diagnostic decision trees for common failure modes, and a CMMS logging standard with required fields and examples.

Industry Tools, Not Toy Projects

Fleet Management Platform

Freedom Robotics, InOrbit, or Formant for real-time telemetry, sensor data, and fleet health monitoring.

CMMS (Fiix / UpKeep / SAP PM)

Computerized maintenance management systems for logging repairs, tracking work orders, and building maintenance datasets.

Excel / Google Sheets

MTBF analysis, spare parts inventory modeling, and maintenance schedule optimization.

Power BI / Tableau

Sensor trend visualization and predictive maintenance dashboards for fleet-wide analysis.

PagerDuty

Maintenance alerting and incident management for anomaly detection notifications and escalation.

Claude

AI-assisted troubleshooting research, diagnostic documentation, and maintenance procedure writing.

Prerequisites

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