SERENA · Project

Plug-and-Play Predictive Maintenance Platform That Cuts Factory Downtime Across Industries

manufacturingPilotedTRL 7

Imagine your factory machines could tell you they're about to break down — before they actually do. SERENA built a plug-and-play system that connects sensors on your equipment to a cloud platform, uses machine learning to spot trouble early, and even gives your maintenance team augmented reality guides to fix problems faster. They tested it in four completely different industries — from elevators to washing machines — proving it works no matter what you manufacture.

By the numbers

Industrial demonstrators completed (white goods, metrology, elevators, steel)

EUR 5,506,493

EU contribution for platform development

Partners in the consortium

Countries represented

TRL 5 to TRL 7

Technology readiness advancement target

Industry partners in the consortium

Total project deliverables

The business problem

What needed solving

Unplanned machine breakdowns are one of the most expensive problems in manufacturing — every minute of downtime means lost production, rushed repairs, and missed delivery deadlines. Most factories still rely on scheduled maintenance (replacing parts on a calendar) or reactive fixes (waiting until something breaks), both of which waste money. What manufacturers need is a system that watches equipment health continuously and warns them before failures happen, without requiring a complete IT infrastructure overhaul.

The solution

What was built

SERENA built a plug-and-play cloud-based platform combining IoT sensors, machine learning for predictive maintenance, and augmented reality for operator support. The system was demonstrated through 4 industrial pilots (white goods, metrological engineering, elevators production, steel parts production) with 15 total deliverables documenting the results.

Audience

Who needs this

Appliance and white goods manufacturers with high-volume production linesElevator manufacturers and maintenance service companiesPrecision engineering and metrology equipment operatorsSteel and metal parts production facilitiesAny discrete manufacturer looking to shift from reactive to predictive maintenance

Business applications

Who can put this to work

White goods manufacturing

enterprise

Target: Appliance manufacturers running high-volume production lines

If you are a home appliance manufacturer dealing with unexpected machine stops on your assembly lines — this project developed a plug-and-play IoT and AI platform that monitors equipment health in real time and predicts failures before they cause costly downtime. It was fully demonstrated in white goods production with results documented across 15 deliverables. The system advances maintenance from reactive to predictive without replacing your existing machinery.

Elevator and lift production

mid-size

Target: Elevator manufacturers and maintenance service providers

If you are an elevator producer or service company struggling to schedule maintenance efficiently across scattered installations — this project built a cloud-based remote monitoring platform with smart sensors and machine learning that flags components heading toward failure. It was demonstrated specifically in elevator production environments as one of 4 industrial use cases. The platform supports remote diagnostics so your technicians arrive already knowing what to fix.

Precision engineering and metrology

mid-size

Target: Precision parts manufacturers and quality-critical machining shops

If you are a precision engineering company where machine drift means scrapped parts and lost margins — this project created an AI-driven predictive maintenance system with AR-assisted operator support, tested directly in metrological engineering settings. The plug-and-play design means it connects to your existing sensors and equipment without a full IT overhaul. It was validated at TRL 5 to TRL 7, meaning it moved well past the lab and into real factory conditions.

Frequently asked

Quick answers

What would it cost to implement this predictive maintenance platform?

The project does not publish per-unit licensing or deployment costs. The full EU contribution was EUR 5,506,493 shared across 14 partners over 3.5 years, indicating significant R&D investment. Contact the coordinator COMAU SPA for commercial pricing and deployment options.

Can this scale to large multi-site manufacturing operations?

Yes — the platform was designed for versatility and tested across 4 different industrial sectors (white goods, metrological engineering, elevators, and steel parts production). Its plug-and-play cloud-based architecture supports remote monitoring and control, which is built for multi-site deployment. The consortium included 10 industry partners across 7 countries.

What is the IP situation — can I license this technology?

IP is held by the 14-member consortium led by COMAU SPA, a major industrial automation company (Stellantis group). Licensing terms would need to be negotiated directly with the consortium partners. As an Innovation Action (IA), results are expected to be brought closer to market.

How mature is this technology — is it ready for my factory floor?

The project explicitly targeted advancing components from TRL 5 to TRL 7, meaning from validated prototypes to systems demonstrated in operational environments. Four industrial demonstrators were completed and documented. This puts the technology past the pilot stage and approaching deployment readiness.

How does this integrate with equipment I already have?

The system was specifically designed as plug-and-play, meaning it connects to existing machinery through IoT sensors and smart devices without requiring a full infrastructure replacement. The cloud-based communication platform manages data remotely, reducing on-site IT burden.

What industries has this actually been tested in?

Four industrial demonstrators were completed: white goods manufacturing, metrological engineering, elevators production, and steel parts production. The project also investigated applicability to automotive and aerospace sectors, showing its cross-industry transferability.

Does this comply with industrial data security and regulations?

Based on available project data, specific certifications or compliance standards are not detailed in the objective or deliverable descriptions. Given that COMAU SPA (a major industrial automation supplier) led the project with 10 industry partners, industrial data handling requirements were likely addressed. Confirm specific compliance details with the consortium.

Consortium

Who built it

The SERENA consortium is heavily industry-driven — 10 out of 14 partners (71%) come from industry, with only 2 universities and 2 research organizations. It is led by COMAU SPA, an Italian industrial automation giant that builds robotic systems for major car manufacturers, which gives the platform immediate credibility for factory-floor deployment. The consortium spans 7 countries (Germany, Greece, Spain, Finland, Ireland, Italy, Netherlands), includes 3 SMEs that bring agility, and covers the full chain from sensor hardware to cloud software to end-user manufacturing. This composition signals that the technology was built by people who understand factory realities, not just academic theory.

COMAU SPACoordinator · IT
TEKNOLOGIAN TUTKIMUSKESKUS VTT OYparticipant · FI
TRIMEK SAparticipant · ES
BEKO ITALY MANUFACTURING SRLparticipant · IT
Maintastic GMBHparticipant · DE
POLITECNICO DI TORINOparticipant · IT
FINN-POWER OYparticipant · FI
EMC INFORMATION SYSTEMS INTERNATIONAL UNLIMITED COMPANYparticipant · IE
ENGINEERING - INGEGNERIA INFORMATICA SPAparticipant · IT
PANEPISTIMIO PATRONparticipant · EL

How to reach the team

COMAU SPA is an Italian industrial automation company (part of the Stellantis group). Their innovation and R&D teams in Turin would be the entry point for licensing or deployment discussions.

Order a report on this consortium See COMAU SPA profile →

Next steps

Talk to the team behind this work.

Want to explore how SERENA's predictive maintenance platform could reduce downtime in your production? SciTransfer can connect you with the right consortium partners and help you evaluate fit for your specific manufacturing setup.

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