GAIA

Keep America running.

Your controllers already report how every motor, drive and engine is running. GAIA reads that data and tells your maintenance team which part will fail, why, and when, in time to fix it at a planned stop.

Request a briefingSee how it works

  1. Every machine on this floor already reports how it runs. Each in its own language. No one is listening.

  2. GAIA connects read-only to what you already run and reads all of it. No new sensors. No changes to your controls.

  3. Every machine is compared with its own history and with machines like it.

  4. GAIA tells you what will fail and how long you have.

  5. Every alert shows the signals behind it, so your team can trust it before they act on it.

  6. The fix is scheduled for your next planned stop. The line keeps running.

Illustration

Pump motor A

Health: Degrading

Deviation from baseline

Motor current+12%
Torque+9%
Temperature58°C

Representative data

Zone 3 drive

Current +3%

Torque +1%

46°C

Representative data

Machining center 1

Spindle load 62%

Spindle speed 8,000 rpm

Representative data

Pump motor B

Current +1%

Discharge 4.1 bar

38°C

Representative data

Pump motor. Likely bearing wear.

About 3 days to failure.

Representative data

Evidence

Motor current+12%
Torque+9%
Temperature58°C

Component: drive-end bearing

Confidence: high

Representative data

Historian
MES schedule
CMMS history
ERP spare parts
CMMS work orders
Planning
Pump motor A
Pump motor B
Zone 1 drive
Zone 3 drive
Machining center 1
Robot controller

Pump motor A

Health: Degrading

About 3 days to failure

Motor current+12%
Torque+9%
Temperature58°C

Work order

Pump motor A, drive-end bearing

Scheduled: next planned stop

Status: Draft

Representative data

The month, replayed

These machines already knew what was failing.

When a line stops without warning, people stand around it waiting for a part. The data that would have warned them was already on the controller.

  • $2.3M an hour

    Idle line at a major automotive plant

    Siemens, The True Cost of Downtime 2024

  • 69%

    of plants have an unplanned outage every month

    ABB, Value of Reliability, 2023

  • 1.9M

    manufacturing jobs could go unfilled by 2033, taking repair knowledge with them

    Deloitte and The Manufacturing Institute, 2024

One automotive line, one month. Illustrative.

Unplanned stops: 5

  • Unplanned stop
  • Warning
  • Planned stop
  • Planned window

Orange: unplanned stop. Lime: warning. Gray: planned stop.

Outage length: Honeywell Intelligrated average. Alert values are illustrative.

Where it runs

The same motors, drives and pumps run every kind of plant.

EtherNet/IPSpeed · Fault codes

Automotive

Conveyors, robots, presses and machining centers. Paint shop fans and pumps.

Automotive
PROFINETMotor current · Torque

Conveyance and material handling

Drive motors, gearboxes and sortation. They run thousands of hours a year under the same load.

Conveyance
Modbus TCPDischarge pressure · Run hours

Heavy industry

Pumps, fans and compressors, and the drives that run them.

Heavy industry
From the field

GAIA called the failure a day ahead.

On a conveyor line, one drive motor was running 40.6°C above its normal. The rest of the line peaked at 8.0°C.

At that temperature, motor insulation ages about 16 times faster than normal. GAIA projected that rate forward and flagged a failure within 24 hours. The mechanic swapped that motor the next morning.

Measured values from a GAIA deployment. Customer, site and machine not named. Aging rate: EASA; U.S. DOE Motor Systems Tip Sheet 3.

GAIA+40.6°C, measuredRest of line: up to +8.0°C, measured
  1. Flagged
  2. Failure expected within 24 hours
  3. Motor swapped next morning

Built for sites that cannot take risks with their network.

  • Read-only connection

    GAIA connects read-only to the systems a site already runs.

  • Cloud or fully air-gapped edge

    Runs in the cloud or entirely on site with no outside connection.

  • No changes to PLC programs

    Your controls stay unchanged.

  • All employees are U.S. persons

    As defined in 22 CFR 120.62.

Aligned with ISO 55001, ISO 13372, ISO 13374.

GAIA
Our ethos

Named for the ground everything grows from.

We named the company GAIA because the work is foundational. When a plant stops, everything that depends on it stops too. Our job is to keep it running.

Read our ethos

Request a technical briefing.

Tell us what equipment you run and how it connects. We will tell you plainly whether GAIA can read it.

Request a briefing