AI-Driven Predictive Maintenance for Workforce and Service Optimization in the Automotive Sector

Abstract

Vehicle owners often use certified service centers throughout the warranty period, which usually extends for five years after buying. Nonetheless, after this timeframe concludes, a large number of owners turn to unapproved service providers, mainly motivated by financial factors. This change signifies a significant drop in income for automakers and their certified service networks. To tackle this issue, manufacturers utilize customer relationship management (CRM) strategies to enhance customer loyalty, usually depending on segmentation methods to pinpoint potential clients. However, conventional approaches frequently do not successfully forecast which clients are most likely to need or utilize maintenance services. This research introduces a machine learning-driven framework aimed at forecasting the probability of monthly maintenance attendance for customers by utilizing an extensive historical dataset that includes information about both customers and vehicles. Additionally, this predictive approach supports workforce planning and scheduling within after-sales service centers, aligning with AI-driven labor optimization frameworks such as those explored in the AI4LABOUR project. Four algorithms in machine learning-Decision Tree, Random Forest, LightGBM (LGBM), and Extreme Gradient Boosting (XGBoost)-were assessed for their forecasting capabilities. Of these, XGBoost showed greater accuracy and reliability in recognizing high-probability customers. In this study, we propose a machine learning framework to predict vehicle maintenance visits for after-sales services, leading to significant operational improvements. Furthermore, the integration of AI-driven workforce allocation strategies, as studied within the AI4LABOUR (reshaping labor force participation with artificial intelligence) project, has contributed to more efficient service personnel deployment, reducing idle time and improving customer experience. By implementing this approach, we achieved a 20% reduction in information delivery times during service operations. Additionally, survey completion times were reduced from 5 min to 4 min per survey, resulting in total time savings of approximately 5906 h by May 2024. The enhanced service appointment scheduling, combined with timely vehicle maintenance, also contributed to reducing potential accident risks. Moreover, the transition from a rule-based maintenance prediction system to a machine learning approach improved efficiency and accuracy. As a result of this transition, individual customer service visit rates increased by 30%, while corporate customer visits rose by 37%. This study contributes to ongoing research on AI-driven workforce planning and service optimization, particularly within the scope of the AI4LABOUR project.