A two-stage framework for early failure detection in predictive maintenance: A case study on metro trains

Abstract

Early fault detection remains a critical challenge in predictive maintenance (PdM), particularly within critical infrastructure, where undetected failures or delayed interventions can compromise safety and disrupt operations. Traditional anomaly detection methods are typically reactive, relying on real-time sensor data to identify deviations as they occur. This reactive nature often provides insufficient lead time for effective maintenance planning. To address this limitation, we propose a novel two-stage early detection framework that integrates time series forecasting with anomaly detection to anticipate equipment failures several hours in advance. In the first stage, future sensor signal values are predicted using forecasting models; in the second, conventional anomaly detection algorithms are applied directly to the forecasted data. By shifting from real-time to anticipatory detection, the framework aims to deliver actionable early warnings, enabling timely and preventive maintenance. We validate this approach through a case study focused on metro train systems, an environment where early fault detection is crucial for minimizing service disruptions, optimizing maintenance schedules, and ensuring passenger safety. The framework is evaluated across three forecast horizons (1, 3, and 6 hours ahead) using twelve state-of-the-art anomaly detection algorithms from diverse methodological families. Detection performance is assessed using five performance metrics. Results show that anomaly detection remains highly effective at short to medium horizons, with performance at 1-hour and 3-hour forecasts comparable to that of real-time data. Ensemble and deep learning models exhibit strong robustness to forecast uncertainty, maintaining consistent results with real-time data even at 6-hour forecasts. In contrast, distance- and density-based models suffer substantial degradation at longer horizons (6-hours), reflecting their sensitivity to distributional shifts in predicted signals. Overall, the proposed framework offers a practical and extensible solution for enhancing traditional PdM systems with proactive capabilities. By enabling early anomaly detection on forecasted data, it supports improved decision-making, operational resilience, and maintenance planning in industrial environments.