Clark: How AI is transforming fleet maintenance and reducing costly breakdowns in trucking operations

Every business today is looking for ways to cut costs without sacrificing efficiency and productivity. Fleets are especially vulnerable to issues beyond their control, whether that’s natural disasters, expanding tariffs, supply chain disruptions, fuel price volatility, changing regulations, and so on.

One technological advance is helping fleets cope with the multitude of challenges they face: artificial intelligence (AI). Last week, I wrote about how AI was helping fleets reduce costs through enhanced route optimization as well as how streamlined delivery times and processes were improving driver morale. But, as Chris Cheetham-West, founder and president of LR Training Solutions, informed members at a recent NationaLease meeting, AI is reshaping every corner of fleet operations, from front-office sales to back-office finance and from drivers on the road to technicians in the shop.

How AI transforms fleet maintenance into a cost-saving strategic asset

Technicians have seen a significant transformation of the maintenance function through AI, especially when it comes to predictive maintenance. According to a recent article in Forbes, AI is helping fleets manage the three most costly maintenance challenges: Costly breakdowns and unplanned repairs; unexpected parts shortages and emergency procurement; and recurring repairs due to quality and skill gaps.

Real-time AI monitoring cuts roadside breakdowns and boosts truck uptime

Regularly scheduled preventive maintenance is still necessary and a vital function; however, it’s what you don’t see during preventive maintenance that may cause the most problems. AI keeps a watchful eye on your fleet 24/7, spotting issues before they become expensive problems.

Fortunately, most new trucks have sensors already built in, enabling AI-driven systems to monitor the truck’s data and analytics in real time, warning the maintenance team about possible equipment failures. As the Forbes article points out, these problems range "from vibration and temperature to pressure and fuel efficiency, to detect anomalies and signal impending failure. Targeted alerts let maintenance teams schedule proactive repairs, long before a breakdown occurs."

Predictive AI identifies critical parts failures to prevent costly delays

When the COVID-19 pandemic hit, organizations that maintained just-in-time (JIT) inventory found themselves scrambling to locate necessary parts and components during supply chain disruption. Switching to overstocking shelves indiscriminately with all parts can be not only costly but also wasteful, with unneeded parts sitting on the shelves for extensive periods of time.

AI, using data and analytics streamed in real time, can forecast which components are at risk of failure. Often, this can be a more systemic issue rather than a single vehicle problem. This will enable maintenance to direct their purchases toward critical high-failure parts and recommend alternatives, if possible, or make these parts priority purchases.

Being able to purchase needed parts well ahead of when they might be needed precludes the need for emergency buys (which will likely be more costly). With the latest AI-connected technology, states Forbes, "reordering could be automated, triggered by predictive parts forecasts and avoiding last-minute scrambling."

Machine learning tracks repairs to optimize fleet technician performance

AI’s machine learning (ML) capability allows it to do much more than simply supply one-off fixes and recommendations. Each repair, current and historical, is fed into the system, enabling AI to analyze patterns, including parts replacements and how each vehicle performs after repairs. Those vehicles that are repeat “customers” for repair can be addressed and assessed for further usage.

AI doesn’t just track repairs; it evaluates technician performance, vehicle history, and repair outcomes to optimize future fixes. It’s immensely valuable to ascertain whether the problem is due to personnel, parts, or the vehicle itself. For techs, this streamlines repairs and ensures the right fixes are made every time.

AI-driven insights increase fleet efficiency, reduce maintenance costs, and improve uptime

According to Cheetham-West, the numbers are impressive: AI-enabled systems can lead to a 12% reduction in maintenance costs; 20% reduction in roadside breakdowns; 8% increase in operational uptime; and 9% increase in technician efficiency.

Nearly every function mentioned above can be handled by diesel techs, and they continue to do so; however, at a time when every second and every dollar matters, early detection and precision repairs powered by AI are not just smart. They are essential to protecting your bottom line.