Integration of Data Analytics and Data Mining for Machine Failure Mitigation and Decision Support in Metal–Mechanical Industry

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Abstract
Background: The growing complexity of production processes in the metal–mechanical industry demands ever more effective strategies for managing machine and equipment maintenance, as unexpected failures can incur high operational costs and compromise productivity by interrupting workflows and delaying deliveries. However, few studies have combined end-to-end data analytics and data mining methods to proactively predict and mitigate such failures. This study aims to develop and validate a comprehensive framework combining data analytics and data mining to prevent machine failures and support decision-making in a metal–mechanical manufacturing environment. Methods: First, exploratory data analytics were performed on the sensor and logistics data to identify significant relationships and trends between variables. Next, a preprocessing pipeline including data cleaning, data transformation, feature selection, and resampling was applied. Finally, a decision tree model was trained to identify conditions prone to failures, enabling not only predictions but also the explicit representation of knowledge in the form of decision rules. Results: The outstanding performance of the decision tree (82.1% accuracy and a Kappa index of 78.5%), which was modeled from preprocessed data and the insights produced by data analytics, demonstrates its ability to generate reliable rules for predicting failures to support decision-making. The implementation of the proposed framework enables the optimization of predictive maintenance strategies, effectively reducing unplanned downtimes and enhancing the reliability of production processes in the metal–mechanical industry.
Funding Information
  • FUNDAÇÃO DE DESENVOLVIMENTO DA PESQUISA—FUNDEP (27194.C+NE.01/2024.12-00)

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