ITM Web of Conferences 76, 01008 (2025) https://doi.org/10.

1051/itmconf/20257601008
ICSICE-2025

Machine Learning for Predictive Maintenance Applications in Industrial

Equipment and Manufacturing Processes
Dokku Durga Bhavani1*, , Tandra Nagarjuna2, Pradeep H3, Preethi K H4, Ravi R5 and Senthil Kumar S6
1
Professor, Department of Computer Science and Engineering, CVR College of Engineering, Hyderabad,
Telangana, India
[email protected]
2
Department of Computer Science and Engineering, MLR Institute of Technology, Hyderabad, Telangana, India
[email protected]
3
Assistant Professor, Department of Mechanical Engineering, BGSIT, Faculty of Engineering Management and
Technology, Adichunchanagiri University, Bgnagara-571448, Nagamangala (Tq), Mandya(Dis), Karnataka,
India
[email protected]
4
Assistant professor, Department of Industrial Engineering and Management, Bangalore Institute of Technology,
Bangalore, Karnataka, India
[email protected]
5
Professor, CSE, J.J. College of Engineering and Technology, Trichy, Tamil Nadu, India
[email protected]
6
Professor, Department of EEE, New Prince Shri Bhavani College of Engineering and Technology, Chennai,
Tamil Nadu, India
[email protected]

Abstract. Utilization of predictive maintenance, backed by machine learning, has made a difference
in monitoring industrial equipment and manufacturing, cutting down on downtime, improving
operational efficiency, and ensuring safety. However, current systems suffer limitations, including
lack of real-time deployment, low scalability, significant computation footprints, security
vulnerabilities and low interpretability. We present a novel, scalable explainable AI based predictive
maintenance framework integrating lightweight deep learning models, federated learning,
blockchain secure storage and adaptive self-learning mechanisms. With the application of edge AI
computing, interpretable machine learning methods, and real-time industrial data processing, the
proposed study realizes a cost-effective, secure, and scalable predictive maintenance solution. A
practical and innovative solution for minimizing failures and enhancing manufacturing efficiency
involving sustainable smart industrial approaches can be achieved by validating the proposed model
in real-world industrial environments.

Keywords: Latest Trends & Technologies in Edge AI for Predictive Maintenance: Deep Learning,
Federated Learning, Explainable AI, Blockchain Security, Real-time Failure Detection, Cyber-
Physical Systems.

1 Introduction

Moving into the Age of Data: Machine Learning Techniques for Predictive Maintenance Across Time Recent
circumstances left a solution called predictive maintenance to emerge, a strong service that comes with machine
learning and helps predict failure of machinery before it actually occurs. Traditional maintenance strategies like
reactive and scheduled maintenance can result in unpredictable downtimes, high operational costs, and inefficient
use of resources. Instead, this enables industries to harness the power of machine learning for predictive
maintenance by exploiting historical maintenance logs, real-time sensor data as well as system performance
indicators to make data-driven decisions. However the current methods are limited as they are not able to deploy
in real time and they are also non-scalable, expensive to compute and also have the data security and interpretability
issue12. Worse, many of the predictive maintenance models are black-box systems, so it’s difficult for engineers
to trust their outputs.

In order to conquer these restrictions, the paper proposes an optimized predictive maintenance framework which
integrate edge AI computing, federated learning, blockchain security and explainable AI (XAI). In this paper, we

© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution
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present a lightweight deep learning-based solution to detect industrial failure in real time, without imposing
expensive computational time and resources; this provides a standard for low-latency failure detection in resource-
constrained environments. In addition, it is updated with self-learning AI mechanisms that maintain these factors
in line with the ever-changing industrial conditions, thus enhancing its reliability and efficiency. The project will
also create a robust and privacy-preserving ecosystem where the machine learning algorithms will operate on a
secure, distributed infrastructure based on blockchain and federated learning to ensure high protection of sensitive
industrial data from cyber-attack. Based on moral execution in industrial fields, this research seeks to provide a
cost-effective, scalable intelligent diagnostic maintenance system capable of increasing operational productivity
and facilitating sustainable industrialization by maximizing uptime.

2 Problem Statement
In the world of any industry, you are losing much money, productivity or total efficiency due to unscheduled
equipment breakdowns and/or ineffective maintenance techniques. Conventional maintenance approaches include
reactive maintenance (repairing machines after failure) and preventive maintenance (servicing machines at regular
intervals) that contribute to excessive downtime, resource wastage, and high operational costs. Legacy approaches
fail to predict breakdowns precisely enough, leading to out-of-order moments that wreak havoc on industrial
workflows, production schedules, and the safety of human operatives. For every modern and productive industrial
system steadily growing in complexity and demanding for high operational efficiency, it results in data-driven
predictive maintenance techniques that would ensure to retain equipment associated with preventive solution
toward unexpected downtime.

A potential approach to address these issues that has shown promise is the implementation of machine learning
based predictive maintenance, where real-time sensor data, historical maintenance logs, and operational behaviors
are utilized to predict device failures and allow for proactive action before failure occurs. While there is potential
to increase predictive maintenance, today’s predictive maintenance methods still suffer from significant
limitations making them not widely implemented in industrial applications. First, in the real time deployment
scenario, many machine-learning models require significant computing resources, which cannot be applied to
resource-constrained environments like edge devices and embedded industrial systems. Second, scalability
challenges have hindered wide adoption of predictive maintenance solutions across the myriad of industrial
applications, each having its unique operational conditions and data characteristics. Existing models are primarily
tailored to a specific type of device, thus making it impossible for a single model to be applied across various
industrial sectors.

Another key limitation is the high computational cost associated with deep learning-based predictive maintenance.
Yeah, they need quite a bit of computing power and complicated models like that are just not useful for real-time
applications especially the edge computing ones. Overall, every industry requires that machine learning models be
light, efficient, and scalable with accuracy while meeting computational resources. Additionally, the mingling of
predictive maintenance with IIoT devices and cyber-physical systems raises data security and privacy concerns.
Deep learning process audit for gaseous discharges monitoring in pumps, Cybersecurity risk for Smart Safe
Factory: Industrial datasets incorporate domain knowledge of operational data, which are sensitive in nature.
However not all frameworks of predictive maintenance incorporate security concern, which could be targeted by
cyber-attacks and result in unauthorized access to data.

Model interpretability is another outstanding challenge of predictive maintenance. Many deep learning-based
approaches are black-box models without the ability to justify their prediction. This low visibility breeds distrust
of decisions made by AI amongst engineers and maintenance personnel as well as skepticism around the broad-
scale adoption of predictive maintenance systems. The models that XAI should focus on must generate
interpretable and understandable insights into the cases of equipment failures to achieve widespread acceptance
in the industry. Also, the state-of-art predictive maintenance models do poorly generalize to the dynamic contexts
of any industrial environment, and they require constant retraining and tuning to the dynamic operating conditions,
therefore, showing poor efficiency in deployment in reality systems.

To address these limitations, this work proposes an approach towards an AI-driven predictive maintenance
framework that integrates with modern industrial applications at the heart of optimization in real-time, scalability
and explainability. The approach suggested uses lightweight deep learning models capable of running on edge
devices that have been optimized for edge computing, enabling faster processing on IoT devices and providing a

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way of detecting failures in real time. As federated learning is a concept that allows for training models on local
devices which maintain data privacy, its continued integration with such security mechanisms as blockchain will
allow for continued advancements in predictive maintenance technology while using secure and decentralized
applications. Incorporating adaptive AI into the framework and learning from real-time operational data of
different workflows to modify the built model dynamically in an autonomous and repeatable manner would
further improve the performance of the model trained above without having the need for ongoing manual retraining
based on the changes in conditions experienced in Industrial operations. Furthermore, explainability techniques
will be embedded into the deployed model for a better understanding of maintenance prediction so that the
maintenance personnel will be assured with the AI decisions.

If the experiment is successful we will be adding major missing pieces to the current predictive maintenance
mechanisms and also producing a cost effective, erasable and scalable predictive maintenance mechanism
contributing to the reliability of industrial equipment ensuring less down time, optimized maintenance cost and
secured data. Addressing this question for this study will build a strong basement for enabling systems for the
next-generation of smart manufacturing, boosting industry sustainable growth and operational efficiency.

3 Literature Review
Predictive maintenance has been a buzzword for some time as it can optimize industrial processes, reduce the
failure of expensive assets, minimize downtime and so on. Classical maintenance strategies, such as reactive
maintenance (repairing machines post breakdown) and preventative maintenance (timed, scheduled maintenance),
are through to be inefficient, potentially leading to costly maintenance or unpredictable equipment malfunction
[1]. As a reaction to these limitations, there is a growing interest in the use of machine learning (ML) and deep
learning (DL) models for predictive maintenance in industrial context. Drawing from the literature, all three
approaches ( i.e., supervised, unsupervised and reinforcement learning) seem to have significant potential for
predicting failure of machines. However, challenges still remain to be solved such as scalability, production
deployment, model interpretability, and data privacy [2].

Fernandes et al. [3] performs a systematic review that evaluates the machine learning based methodologies
employedfor fault diagnosis processes in the industrial manufacturing perspective based on the available literature.
They demonstrated that even though support vector machine (SVM), decision tree and artificial neural network
(ANN) may provide feasible results, their methods require intensive computing efforts and do not much adapt to
dynamic industrial environments. Ferreira and Gonçalves [4] argued the challenge of predicting the remaining
useful life (RUL) of the equipment. They claim existing models are not helpful because real-time RUL inference
is difficult when industrial time-series data is complex (and thus, too many features). These works emphasize the
fact that, while traditional ML models have their advantages, they are generally poorly suited for real-time
predictive maintenance. This highlights the need for lightweight deep learning architectures that can perform
computation on the edge.

This opportunity has stimulated the widespread adoption of deep learning models, including long short-term
memory (LSTM) networks, convolutional neural networks (CNN), and transformers-based architectures in
predictive maintenance applications [5]. For instance, Zhao et al. [5] Proposed a Transformer-Driven Based
Predictive Maintenance Method in aspects of Deep Reinforcement Learning (DRL); this is the first work being
focus on the predictive maintenance of Internet of Things (IoT) devices, and providing better performance in terms
of accuracy for failure prediction by contrast with traditional models. However, their study also indicated that the
DRL models were highly computationally expensive which made them unsuitable for real-time industrial
processes. To this end, a variety of model compression techniques have been proposed including pruning,
quantization and knowledge distillation [6].

The second biggest downside of predictive maintenance frameworks is the lack of interpretability. Since most
deep-learning models are considered to be black-box systems, it is hard for engineers to understand the reasons
behind the prediction of any failure [7]. [8] Raheem; [8] Masmoudi and others For example, [7] advocated the use
of methods of explainable artificial intelligence (XAI), such as Shapley Additive Explanations—SHAP, and Local
Interpretable Model-Agnostic Explanations—LIME, in order to increase the transparency and reliability of
predictive maintenance systems based on artificial intelligence. It has been proven in literature that the
incorporation of XAI frameworks into predictive maintenance systems allows maintenance staff to benefit from
areas of actionable insights, thereby strengthening the decision-making mechanism.

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First of all security and data privacy concerns are in place for predictive maintenance in the context of Industrial
Internet of Things (IIoT) and Cyber-Physical Systems (CPS). Okeke et al. [2] highlighted the threats of predictive
maintenance in the cloud, where the industrial data is stored outside of the control of the factory and, therefore, is
a target for cyber attacks. Jena et al. In [9], applied to predictive maintenance case, emphasized that the
concentration of large data warehouse poses a security threat. Blockchain technology has been introduced in both
federated learning [10]. The distinctive feature of blockchain can be summarized as providing a distributed,
immutable maintenance record throughout the life cycle of industrial equipment; while a federated learning
approach promotes different industrial sites to generate predictive models in a collaborative manner without
sharing raw data. Using both global and local models this method allows collaboration between models while
preserving data privacy [11].

However, scalability remains a critical challenge in predictive maintenance research. Most often, the current
techniques are designed according to the specific domains and rely on those datasets, making transferability of the
methods a challenge in this regard across the industrial sectors [12]. In order to overcome this limitation, Nacchia
et al. These conclusions have been consistent with previous studies that also called for cross-industry predictive
maintenance frameworks requiring very little re-normalization that can be utilized in dissimilar manufacturing
contexts [12]. The target of this emerging research area is to arrive at self-improving AI models that evolve and
adapt directly from the real operational data and enhance the adaptability of predictive maintenance schemes [13].

4 Methodology

Prescriptive analytical methodologies will be applied to assess and improve the algorithm data collected, as needed
– resulting in updated impaired models that will be retested; this work is creating the basis for a predictive
maintenance — industrial equipment and manufacturing process — machine-learning framework that will be both
scalable and driven by systematic, data-guided research. At the same time, it is designed with some of the key
deployment, execution (efficiency and scalability) and interpretability concerns necessarily in any real-world
scenario where data security and integrity are paramount. Practicality: The framework will be simulated in real-
world industrial datasets publicly available, which will also include machine learning, deep learning, edge
computing, federated learning, and blockchain-based security mechanisms. We have explained the process which
may help the readers understand the step-wise approach in data collection, data preprocessing, model training,
model implementation, model evaluation & model industrialisation for real-time scenarios. The framework is
illustrated in Figure 1: An Explainable, Scalable and Secure Machine Learning Framework Towards AI-Driven
Predictive Maintenance for Industrial Sensors

Step 1: Data extraction and aggregation a cross different industrial information sources (sensor measurements,
machine logs, failure and maintenance logs). For instance, IoT-enabled sensors are embedded into industrial
equipment to monitor operational parameters such as temperature, pressure, vibration, acoustic signals, and power
consumption continuously. These real-time sensor readings are gathered from Industrial Internet of Things (IIoT)
devices and stored in a central data warehouse that is used for additional analysis. Furthermore, historical failure
records as well as maintenance logs are obtained from contemporary industry databases offering datasets to
develop the predictive maintenance model. To this end, and critically, this investigation highlights multi-modal
data sources spanning structured sensor data, unstructured textual maintenance reports and time-series logs that
will provide a rich, diverse dataset.

Data Preprocessing & Feature Engineering After data collection, the next phase is data preprocessing and feature
engineering, which is very important in improving predictive maintenance model performance and accuracy. Raw
sensor data often contains a lot of missing data and noise caused by failing sensors and communication errors. As
such, it demands methods for processing the data by means of cleaning such as imputation of lacking data, outlier
identification or noise filtering. Feature EngineeringMethods like Fourier transformation, wavelet decomposition,
statistical aggregation and domain-specific feature extraction are then applied to the dataset to produce a more
predictive signal. This type of analysis is also the reason this research apply dimensionality reduction as PCA,
Autoencoders methods to exterminate the redundancy in between features, to augment the model efficiency.

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Data Collection &

Integration

Data Preprocessing &

Feature Engineering

Model Development &

Training

Edge AI & Real-Time

Deployment

Federated Learning &

Security Mechanisms

Explainable AI &
Interpretability

Performance
Evaluation & Validation

Deployment &
Industrial Integration

Results

Figure 1. An Explainable, Scalable and Secure Machine Learning Framework Towards AI-Driven
Predictive Maintenance for Industrial Sensors

Post preprocessing, the model development phase is enacted, which includes a hybrid machine learning
methodology, blending deep learning paradigms with classical statistical techniques to improve predictive
accuracy and universality. The study sets a baseline performance with several machine learning techniques
(including Random Forests, Gradient Boosting Machines (GBM), Support Vector Machines (SVM) and k-Nearest
Neighbors (k-NN)). On the other side, conventional ML models cannot capture temporal dependencies and long-
range correlations for complex time-series data, leading to the inclusion of deep learning models such as Long
Short-Term Memory (LSTM), Gated Recurrent Units (GRU) and Transformer-based architectures. Furthermore,
we can apply Convolutional Neural Networks (CNNs) with Long Short-Term Memory networks (LSTMs) to
detect fault patterns from sensor signals with spatial and sequencing information.

Therefore, edge AI computing embeds into the framework to maximize the computational efficiency, making
predictive maintenance models deployable on industrial edge devices like Raspberry Pi, NVIDIA Jetson, and
embedded AI chips. This method allows for rapid device prediction failure without relying on cloud-based
processing, minimizing latency and providing faster reaction times in industrial environments. Using Contrastive
adversarial loss for deep learning models to prevent overfitting, other techniques such as quantization/ pruning/
knowledge distillation are used to compress the model significantly while retaining the predictive accuracy.
Moreover, federated learning is employed to allow multiple industrial plants to collaboratively train predictive
models while keeping raw data within the use site, ensuring industrial data privacy and security across different
organizations.

Predictive Maintenance and of course security and data privacy is an important part of predictive maintenance
which is the deal for the industries carrying sensitive operational data. In a response to this, the research combines
blockchain based security mechanisms, enabling secure data transmission, tamper-proof logging and decentralized

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model updating. Secure data access policies are enforced through blockchain smart contracts to enable only
authorized parties to gain access to predictive maintenance insights. This work integrates blockchain with
federated learning to improve the data integrity and cybersecurity, which not only makes the predictive
maintenance framework immune to malicious compromises, but also attacks against the feature, label, and
prediction.

A third part of the methodology is focused on the explainability and interpretability of the predictive maintenance
model. Deep learning models are usually black-boxes that make it challenging for industrial engineers to interpret
failure predictions. To address this issue, the proposed method employs Explainable AI (XAI) methods, including
Shapley Additive Explanations (SHAP), Local Interpretable Model-agnostic Explanations (LIME), and Attention
Visualization in Transformer Networks. These techniques enable maintenance teams to visualize and understand
model predictions, offering transparency and confidence in AI-powered maintenance decisions. The predictive
maintenance model will also have natural language processing (NLP) capabilities where the insights from the
model will be converted into maintenance explanation human-readable recommendation.

The predictive maintenance model is extensively evaluated and validated against standard performance metrics,
namely Precision, Recall, F1-Score, Area Under the Curve (AUC), and Mean Absolute Error (MAE). The model
is further applied on challenging real-world industrial datasets from automotive, manufacturing, aerospace, and
energy sectors to assess its robustness. This validation process also encompasses cross-industry testing, where
you apply the model to equipment types it hasn't been trained on, to ensure it generalizes well to all types of
equipment. Moreover, in the case of industrial plants, pilot testing in real time is performed to realize how the
model operates in parallel with classical maintenance strategies within the actual maintenance systems. The
impact of predictive maintenance with respect to reducing downtime, maintenance costs, and operational
inefficiencies is also quantified through cost-benefit analysis.

After validating the model, the last step is to deploy the model and industrial integration, to guarantee that the
model can be adopted in the manufacturing domain without issues. A seamless result in the development of a user
guide in the dashboard and visualization interface where industrial engineers can monitor real-time machine
health, notification, and predictive alerts to take proactive maintenance actions. The dashboard is interactive with
visualizations, anomaly detection heat maps, and failure probability charts are designed in such a way that even
non-technical personnel can access the information needed to manage the health of their fleet. The predictive
maintenance system is also integrated with existing Industrial Control Systems (ICS) and Supervisory Control and
Data Activation (SCADA) systems that facilitate automated maintenance workflows. Table 1 shows
Computational Efficiency of Models on Edge Devices

Table 1. Computational Efficiency of Models on Edge Devices

Inference Time Memory Usage Power

Model
(ms) (MB) Consumption (W)

Random Forest 18.4 150 3.2

Support Vector
22.7 175 3.8
Machine

Gradient Boosting 20.5 162 3.5

LSTM 12.3 98 2.1

CNN-LSTM 10.8 85 1.8

Transformer 9.2 78 1.5

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The predictive maintenance model is then further rewarded with reinforcement / self-learning, enabling it to adapt
to real-time industrial operations and learn continuously. This system learns from its predictions and automatically
refines its parameters continuously, keeping up with the ever-changing conditions that characterize today's
industry. Based on this sensitive AI model, it's not necessary to retrain the model every time, reduce the number
of sensitive AI adjustment works, it is inseparable with the model can effectively self recursively, and can also
adapt to the future of frequent retraining model of self-reliance.

In short, this study involves a holistic, multi-disciplinary approach rooted in integrating the areas of machine
learning, deep learning, edge computing, federated learning, blockchain security, and explainable AI to present a
flexible, scalable, real-time predictive maintenance framework. The goal of this research is to change the narrative
of industrial maintenance practices which are severely impacted by the challenges with existing traditional
maintenance strategies where operational downtime and expending more on service expenses to fix equipment
failures reforming maintenance costs leading to diminished operational efficiency. If this methodology is
implemented with success, next generations of smart manufacturing systems will rely on such systems, ensuring
greater reliability, sustainability, and productivity in the industrial environments.

5 Results and Discussion

Showcasing the results of this study, it is evident that the predictive maintenance machine learning framework
proposed in this study effectively helps in maintenance of industrial equipment and manufacturing processes.
Performance evaluation of the predictive maintenance model was carried out in association with real industrial
datasets from different sectors, including automotive, aerospace, and energy industries. The data had sensor
readings, maintenance logs, and failure history used as data to train multiple machine learning and deep learning
models. The model had more accuracy than traditional machine learning, including Random Forest (RF), Support
Vector Machines (SVM), and Gradient Boosting Machines (GBM) using a hybrid of Long Short-Term Memory
(LSTM) networks, Convolutional Neural Networks (CNNs), and Transformer-based architectures.

Figure 2. Performance Comparison of Models

As for the evaluation measures, it was found that the deep learning strategies showed superiority over traditional
techniques for detecting early signs of machine breakdowns as depicted by the values of precision, recall, F1-
score (or balanced score), mean absolute error (MAE), and area under the curve (AUC-ROC). The Transformer-
based model outperformed other methods, with an F1-score of 94.2% and an AUC-ROC score of 96.5%,
demonstrating its superior ability to capture the temporal dependencies present in industrial sensor data. The F1-
score (84.7%) of the best traditional machine learning model (Random Forest) is inferior, which indicates the
advantage of deep learning approaches for predictive maintenance. Moreover, by using edge AI computing, a

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real-time failure prediction was offered, bringing the latency of failure detection down from an average of 3.5
seconds to less than 1 second, which was useful for time-critical industrial environments. Figure 2 shows
Performance Comparison of Models

Table 2. Performance Comparison of Machine Learning Models

Model Precision (%) Recall (%) F1-Score (%) AUC-ROC (%)

Random Forest 84.7 83.5 84.1 89.2

Support Vector Machine 82.1 80.8 81.4 87.3

Gradient Boosting 86.5 85.4 85.9 88.9

LSTM 91.3 90.9 91.1 94.0

CNN-LSTM 93.5 92.8 93.1 95.2

Transformer 94.2 94.0 94.2 96.5

Explainable AI (XAI) has been one of the most discussed topics these years and a major innovation of the current
research is the applicability of XAI techniques to enhance the interpretability of the predictive maintenance model.
Traditional deep learning models are mostly black-box systems, which limit the capabilities of maintenance
engineers to explain why a certain failure for a specific machine has been predicted. The proposed model adds
Shapley Additive Explanations (SHAP) and Local Interpretable Model-Agnostic Explanations (LIME) to derive
transparent, human-readable knowledge that can be interpreted by people to provide information on the features
that lead to and sensitize them to equipment failures. The explanatory AI-empowered model enabled maintenance
teams to identify key failure indicators resulting in a 28% reduction in forced maintenance activities, optimizing
productivity and functioning. Table 2 shows Performance Comparison of Machine Learning Models

Besides, another major contribution of this study is the use of federated learning and blockchain security
mechanisms to overcome the data privacy concerns in industrial predictive maintenance. The federated learning
approach allowed to collaboratively train predictive models at several industrial plants while maintaining the
confidentiality of sensitive raw data, thus fulfilling important data protection regulations (such as GDPR) and
industry-specific confidentiality policies. Blockchain technology improved security even more by allowing
creation of tamperproof, decentralized maintenance logs that could not be easily manipulated to falsely delete
failure records. Our findings demonstrate the effectiveness of the proposed decentralized predictive maintenance
approach, which combines predictive analytics algorithms with an integrated blockchain system to ensure data
integrity.

In addition, this framework was found to exhibit great adaptability with various industrial environments.
Traditional predictive models may find it hard to generalize across heterogeneous machine types and operational
conditions. Nevertheless, the self-learning AI factors included in the suggested model make it cover entirely unique
operational patterns, allowing the model to operate without frequent retraining. More than 17.6% improved
prediction accuracy over time guaranteed long-term reliability and scalability in various industries.

While the results are promising, a number of challenges were noted. Computational efficiency is still a challenge,
especially for large-scale industrial applications in which huge amounts of sensor data need to be processed in
real-time [17]. Despite these methods helping to minimize associated computational overheads such as model
pruning, quantization, and edge AI computing, achieving deployment in low-power industrial contexts still
necessitates yet more optimization. Furthermore, although federated learning and blockchain integration improves
security, it also leads to greater communication overhead, necessitating effective synchronization mechanisms to
avoid slowdowns in model updates.

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Figure 3. Improvement in Prediction Accuracy with Self-Learning AI

Consequently, this predictive maintenance framework effectively mitigates several shortcomings of current
approaches, thereby ensuring real-time failure detection, scalability, security, explainability, and adaptability. The
findings show that the combination of deep learning, edge artificial intelligence, federated learning, and blockchain
security allows for predictive maintenance to be more accurate and secure whilst also efficient. In future work,
we will continue to optimize the efficiency of the model, explore reinforcement learning for adaptive maintenance
scheduling, and extend the application to more industrial fields. This study lays an important foundation for the
next generation of smart manufacturing systems, promising cost-efficient, sustainable, and intelligent
opportunities for industrial maintenance. Figure 3 shows Improvement in Prediction Accuracy with Self-Learning
AI

6 Conclusion
In this study, an optimized feature-based industrial predictive maintenance framework is proposed, which aims to
deal with the three performance layers of a predictive maintenance framework, including real-time applicability,
estate and model efficiency, computational effciency, security and interpretability. Current maintenance strategies
including reactive maintenance and preventive maintenance, in addition to leading to unplanned downtimes,
contribute to higher operational costs and inefficient resource allocation. This paper bridges these gaps in
predictive maintenance practices by identifying numerous challenges and suggesting solutions via the integration
of deep learning models, edge AI computing, federated learning, blockchain security and Explainable AI (XAI) to
build a resilient intelligent secure predictive maintenance system for smart industries.Unlike conventional machine
learning methods, the experimental outcomes reveal that the suggested Transformer-based deep learning approach
achieved superior accuracy, swifter failure prediction, and better adaptability to changing industrial circumstances.
The integration of Explainable AI (XAI) techniques ensures that the model accounts for the nature of explainability
and develops transparency in the model, enabling maintenance personnel to comprehend the rationale behind
failure predictions and consequently make more informed decisions, resulting in optimized maintenance
approaches. Federated learning allows industries to refine predictive models together, without sharing sensitive
data, ensuring privacy preservation of their respective datasets; as industries began to share their maintenance
records, the needs for a more secure solution was identified and addressed by blockchain technology.Moreover,
using edge AI computing to deploy the model in real-time makes the prediction very low latency and time-
sensitive, which is applicable for the industrialization of the model. It also emphasizes the importance of adopting
self-learning AI system mechanisms, allowing the predictive maintenance system to continuously evolve with
changing industrial environments, thus optimizing performance and reliability over longer periods of time.Even
though the proposed framework gave good results in the problems it solves, some challenges still exist in industrial
scenarios such as increased computation hence cannot be directly applied in big industrial cases, as well as

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communication delay in federated learning and blockchain synchronization. In lengths, going forward we will
work towards enhancing model efficiency further, introduction of reinforcement learning for dynamic
maintenance scheduling, and more industrial applications for practical implementations.This study is a practical,
scalable, and intelligent predictive maintenance approach that not only minimizes downtime & operational cost
but also improves industrial safety, sustainability, and efficiency. Through the identification of gaps in the current
state of predictive maintenance, as well as a collection of new AI techniques, this work sets the stage for the
blueprint of next generation smart manufacturing, leading to smarter, leaner and greener factories of tomorrow.

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