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Facilities management / Aviation

Predictive maintenance for airport facilities with IoT

A major airport maintained over a million square feet of terminal reactively: HVAC, lifts, escalators and baggage systems were fixed after they failed. We built an IoT-driven facilities platform that sees faults coming and schedules the work before passengers notice.

ClientMajor airport (confidential)
IndustryFacilities management / Aviation
What we deliveredIoT sensor platform, facilities management software, analytics
Predictive maintenance for airport facilities with IoT
PredictiveFaults flagged before failure
MinutesFault-to-engineer response
LowerEmergency call-out spend

01 The challenge

Emergency call-outs were expensive and disruptive, escalator and lift outages hit passenger flow at the worst moments, and the maintenance team had no data on asset condition — only a log of what had already broken. Contract SLAs were monitored on spreadsheets and the annual unplanned-maintenance bill kept growing.

02 What we did

  • Sensor layer on critical assets — vibration, temperature, current draw, run-time and door cycles — connected through the airport's network
  • Facilities platform with an asset register, live condition dashboards and threshold-based alerts
  • Predictive rules and models that flag assets drifting out of normal operating range days before failure
  • Work-order integration: alerts create tickets, assign engineers and track response times against SLA
  • Contractor and compliance reporting generated automatically for statutory inspections

03 The results

  • Unplanned incidents on monitored assets fell substantially in the first year
  • Escalator and lift availability improved to near-continuous
  • Fault response measured in minutes, with engineers dispatched automatically
  • Significant reduction in annual emergency-maintenance spend

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