Case Study

Large turbine maker realizes 15% savings on equipment maintenance and 10% improvement in uptime

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Client: One of the world’s largest gas turbine manufacturers

Industry: Industrial manufacturing

Business need addressed:
Achieving higher revenue growth at better margins by ensuring high asset uptime and lower service and part costs

Genpact solution:
Seamless remote connectivity and monitoring and proactive turbine health management

Business impact:

  • Increased asset uptime by 10% and reduced maintenance costs by 15%
  • Robust and scalable connectivity infrastructure
  • Enhanced customer satisfaction

Business challenge

The client is rapidly expanding in key markets and wanted to set up an integrated asset management system to support this growth. Key challenges faced were the following:

  • Sustaining a constant level of remote connectivity, causing difficulties in checking on the condition of the gas turbine and control systems
  • Ensuring high-asset uptime in the field using remote troubleshooting and fault detection
  • Lack of availability of skilled and trained resources for ongoing health monitoring and analysis

These factors led to increased unscheduled maintenance, high penalty costs, an increasing number of false alarms, and ultimately low uptime and efficiency of the gas turbines.

Genpact solution

Seamless remote connectivity and monitoring

  • Established an On-Site Monitoring system (OSM) as an interface between the client’s remote sites with the global installed base (IB). This involved identifying and configuring the best-suited satellite device for optimum data transfer rates, installing these devices on the IB, and then testing on-site to check equipment readiness

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  • Replaced legacy system connections with updated remote connectivity modules, enabling more effective data logging, to maintain higher connectivity uptime

Proactive turbine health management

  • Asset operation digitization by automating data gathering and management
  • Asset performance engineering with our engineering and rotating machinery experts to ensure highly accurate turbine efficiency tracking and real-time analysis
  • Predictive maintenance and optimized service levels by implementing automated failure detection and forecasting mechanisms

Business impact

  • Improved equipment health – Increased asset uptime by 10%, reduced equipment maintenance costs by about 15%, and enhanced customer satisfaction through 20% faster issue resolution
  • Robust and scalable connectivity infrastructure – 97% connectivity uptime against a baseline of 65%, 30% improvement in deployment time, and 40% decrease in cost per deployed unit

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