Less Downtime
More Throughput
Lower Cost/ton
PlantOS™ tells your operators exactly what to fix before it breaks — then proves the fix worked.
Prediction ≠ Outcomes.
TRUSTED BY THE WORLD'S HEAVY INDUSTRY LEADERS
The PlantOS™ outcomes scorecard
1000
Plants Digitalized
Globally
167,837
Hrs. of Unplanned Downtime Saved
up to
99%
Prescriptions Acted
Upon
up to
10%
Less Maintenance Cost
up to
2%
Less Conversion Cost
up to
2.5%
More Throughput
*Note – Data as of August 06, 2026 Source – PlantOS™ Digital Reporting System – User-validated True Positives & False Negative Rate
PlantOS™ is Infinite Uptime's Prescriptive AI Platform for heavy manufacturing, delivered as Production Outcomes as a Service. Where predictive tools warn that equipment may fail, PlantOS™ tells operators which fault to fix, why, and by when. Operators validate whether the prescription worked, and that feedback sharpens the next one. It turns equipment and process data into validated production outcomes: less unplanned downtime, lower maintenance cost, and higher throughput.
Where predictive maintenance stops
Why do some failures slip past
predictive maintenance?
Most monitoring tools watch only the machine. Many costly failures start in the process around it and speed up mechanical wear.
Equipment-borne
Wear that develops inside the machine
Infinite Uptime's PlantOS™ is Vertical AI trained on your equipment type and your process, so your team catches the failures generic AI misses.
Process-induced
Stress from how the equipment is run
Operator Validated Outcomes
Validated on site and signed off by the operators who run the plant.
JSW Steel rolled PlantOS™ out across 139 plants in India and the USA and cut unplanned downtime 2X in under a year.
Read the JSW Steel story
Across 14 plants, Indorama Ventures caught developing equipment faults early with PlantOS™ and cleared them during planned shutdowns instead of forced ones.
Read the Indorama Ventures story
JK Tornel acted on PlantOS™ vibration alerts on its Banbury mixer line early enough to schedule repairs instead of absorbing a line stoppage.
Read the JK Tornel story
Vedanta Group used PlantOS™ to intervene on failing assets before they stopped production, converting avoided breakdowns into recovered output.
Read the Vedanta Group story
SPCC replaced reactive firefighting with a daily prioritized work order queue from PlantOS™ and fixed critical assets before they failed.
Read the SPCC story
With PlantOS™ live across 27 plants, Coromandel International planned maintenance around real asset health and took equipment down on its own schedule, not the failure's.
Read the Coromandel International storyAll figures validated by Customer's Reliability & Operations teams via PlantOS™ Prescription Engine
Client Testimonials
How PlantOS™ Works
From a signal on the floor to an
outcome the enterprise can see
One loop runs continuously across your plant. Each pass sharpens the next prescription.
-
01
Sense
Continuous data from sensors, PLC and historian, inspections and oil analysis.
-
02
Understand
Root cause identified, and whether production is at risk.
-
03
Prescribe
The corrective action issued as a work order, with severity.
-
04
Act
The operator executes the work order and the fault clears.
-
05
Validate
The operator confirms the outcome, so it is recorded rather than estimated.
-
06
Outcomes
Uptime, throughput and cost per ton move, and the impact rolls up into your enterprise systems.
The 99% Trust Loop. Every prescription is validated by the operator who acts on it, and each validation sharpens the next one.
Explore the platform
Deep domain AI on critical assets, flexible coverage everywhere else.
Infinite Uptime's PlantOS™ applies equipment-specific AI to the assets that can stop production, and scalable wired or wireless coverage to everything else. A single risk model underneath turns all of it into maintenance, spares and CAPEX decisions.
01 · The Active Defense
AI Shields
Equipment-specific AI on the machines that can stop production. Each Shield is trained on one asset type, so it tells a mechanical fault apart from a process upset instead of flagging both as noise.
- Mechanical AI Shields on Crane, Run-Out Table, and more
- Mechanical plus process AI Shields on Kiln, Filler, and more
- Dynamic FMEA with 24x7 human-in-the-loop CoE review
02 · The Foundation
Flex Reliability
Coverage for the rest of the plant, sized to what each asset is worth. Wired continuous monitoring where a stoppage still costs money, wireless periodic monitoring where a scheduled health check is enough.
- Wired coverage using piezoelectric and MEMS sensing technology
- Wireless MEMS, with self-powered tags where cabling is impractical
- Existing third-party sensor data ingested, no rip and replace
03 · The Orchestration Layer
Plant Fusion
Infinite Uptime's PlantOS™ ranks what to maintain, stock and replace by risk. Scope escalates from asset to equipment, process, plant and fleet, and every job an operator closes returns as a label that sharpens the next decision.
- RBI, RCM and FMEA applied to every failure mode
- Open API and MCP carrying prescriptions into enterprise systems
- Validated outcomes returned as labels that sharpen the fleet
How long does it take to deploy PlantOS™ Prescriptive AI?
The Path to Reliability Outcomes Your Operators Trust - in 90 Days
No
rip-and-replace — works with your
existing systems. First prescription in 2 weeks.
Scale with confidence.
Week 1-2
Solution Deployment
- 100% equipment coverage Day 1
- Rotating + static equipment + process context
- Baseline assessment complete
Week 3-4
First Prescription
- Operator validation workshop
- Digital signoff trained
- First fault prescribed
Month 2
Scale & Optimize
- Additional equipment lines
- Process efficiency modules
- KPI baseline established
Month 3
Plant-Wide
- Board-ready ROI report
- Expansion planning
- 99% Trust Loop complete
