Predictive Analytics Solutions for Reducing Downtime

How real-time data and AI drive smarter maintenance

A technician looks at a handheld digital device while working on a semi-truck.
Penske is redefining vehicle maintenance by combining real-time vehicle data and advanced artificial intelligence (AI) to detect maintenance issues early, reduce unscheduled repairs and transition from reactive to proactive, predictive maintenance.

With more than 430,000 vehicles under management, Penske has built a connected fleet ecosystem that pulls together telematics data from equipment, telematics devices, electronic logging devices, other on-board systems, and Penske’s own maintenance and repair histories to get a comprehensive picture of performance and vehicle behavior.

“We are getting more than 3,500 messages per second off of a vehicle,” said Tim Haynes, vice president of digital and customer data. "Right now, from our trucks at Penske, we receive more than 300 million messages daily."

Penske creates various scenarios by reviewing road calls, and AI can predict a time-to-failure for units that hit for an active scenario. The information allows Penske to trigger alerts or interventions for proactive maintenance. Data also prevents over-servicing of vehicles, which can also increase downtime.

AI can analyze massive datasets, predict outcomes and simulate various scenarios to find the best solutions. Penske’s maintenance technology enables teams to determine whether an issue needs to be addressed immediately or can wait until the next scheduled maintenance interval. More importantly, AI can help technicians uncover the root cause of a problem, increasing efficiency and reducing the need for return visits.

The constant flow of data from equipment also powers remote diagnostics while vehicles are en route, allowing Penske to evaluate emerging issues as soon as sensors detect abnormalities without bringing equipment into the shop. When a fault code is triggered, Penske's 24/7 assistance team receives the code, location and context instantly, enabling rapid triage.

Real-World Results

Several fleets have already reported measurable benefits of AI-driven maintenance. Darigold, a major dairy cooperative, uses AI-powered insights through Penske’s Catalyst AI™ to closely monitor tire wear, hose conditions and fuel efficiency against industry benchmarks. When Catalyst AI identifies deviations, the fleet can investigate the cause and correct issues before they escalate into failures or missed deliveries.

“All of our management teams use Fleet Insight™ almost daily to check on preventive maintenance, equipment status, and overall visibility,” said Brian Harper, fleet operations leader at Darigold. “It gives fleet managers the data they need at their fingertips to run the operation and know exactly where they stand.”

Honeyville has reported similar benefits. Marcasa Ahlstrom, corporate transportation manager for the grain and food processing supplier, said Catalyst AI allows the fleet to dial down into its preventative fleet-maintenance routine to stay on top of performance and identify potential issues before they become costly problems.

A Data-Driven Future

As commercial vehicles become more complex and connected, real-time vehicle intelligence, AI capabilities and data-guided diagnostics will continue to transform fleet maintenance, empowering fleets and service providers to strengthen maintenance programs, enhance operational efficiency, and maximize uptime.

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