Work

A Replay-Based Big Data Framework for Predictive Maintenance in Industrial IoT

Year: 2026

Type: article

Abstract: The rapid growth of Industrial IoT (IIoT) has led to large volumes of sensor data, increasing the need for scalable and data-driven maintenance solutions. This paper presents a replay-based streaming framework for predictive maintenance that integrates Apache Kafka for data ingestion, Apache Spark Streaming for distributed processing, and an LSTM-based model for fault prediction. The NASA CMAPSS FD001 dataset is used in a controlled streaming simulation to evaluate the feasibility of processing multivariate degradation data under different workload levels. To reduce data leakage, engine units are split before sliding-window sequence construction. Experimental results show that the LSTM model achieves 90.4% accuracy, 89.2% precision, 87.6% recall, and an F1-score of 88.4% on the test set. Under the controlled replay conditions, the observed post-Spark prediction-stage latency remained below 600 ms across the evaluated workload levels. Since the Kafka and Spark timing components and the original micro-batch interval were not retained separately, these measurements should not be interpreted as end-to-end pipeline latency. The results demonstrate the feasibility of integrating stream-processing technologies with deep learning for predictive maintenance, while full end-to-end latency and horizontal scalability remain subjects for future evaluation.

Source: Systems

DOI: 10.3390/systems14101255

Authors: Muhammad Asad, Yaser Alhasawi, Salem Alghamdi, Dana Sami Bakry, Abderahman Rejeb

Institutions: University of Plymouth, King Abdulaziz University, Institute of Public Administration, Széchenyi István University

Language: English

Topic: Machine Fault Diagnosis Techniques

Subfield: Control and Systems Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: gold

Estimated APC paid: $2,896