Predictive Maintenance in Manufacturing
A manufacturing plant wants to predict when a critical milling machine is about to fail. The dataset contains vibration and temperature sensor logs recorded every second for two years. Failures occurred only 5 times in two years. The plant manager trained a Logistic Regression model and is thrilled that it achieves 99.99% accuracy.
The data science team steps in and realizes the accuracy metric is a trap. They switch the evaluation metric to Recall and the Precision-Recall AUC. They discover the Logistic Regression model has a Recall of 0%—it never once predicted a failure. They switch the approach to an Anomaly Detection framework using Isolation Forests, treating failures as outliers rather than a standard binary classification task.
By shifting the workflow to Anomaly Detection and optimizing for Recall, the new system correctly predicted 4 out of the next 5 failures hours in advance, saving the plant an estimated $2.5 million in unplanned downtime, despite an increase in false positive alerts.