Engine Failure Prevention and Warranty Recovery
Repeated engine failures led to rising costs and operational disruption for a fleet operator. Intangles uncovered hidden risk patterns, prevented multiple failures, and enabled successful warranty recovery through data-backed validation.
Situation
Over a period of 2 to 3 months, multiple engine failures were reported across the fleet. The absence of visible alerts raised concerns around early warning visibility. The failures resulted in increased downtime and high maintenance costs, prompting the need for a deeper evaluation of underlying operating conditions.
Solution
Analysis of vehicle data revealed frequent high RPM behavior during cold starts, along with repeated engine overrun events prior to failure incidents. Fleet-level assessment confirmed that these patterns were consistent across vehicles, indicating a systemic issue linked to driver behavior. Intangles enabled visibility into these patterns by correlating engine load, RPM behavior, and temperature signals, allowing early identification of high-risk operating conditions.
Success
The customer implemented corrective actions focused on driver awareness and monitoring of engine operating behavior. In a subsequent failure incident, the OEM rejected the warranty claim citing overrun duration and a fault code. Intangles analysis confirmed that no engine overrun events were present and the fault code was inactive. Further evaluation identified abnormal coolant temperature behavior as the likely cause. These findings were presented in a joint discussion with the OEM, supported by data- backed validation.
Outcome
- Warranty claim approved based on data-backed validation
- Prevention of 5 to 6 potential engine failures within 2 months
- Reduction in downtime and maintenance costs
- Estimated savings of ₹10 to ₹12 lakhs
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