FLUID: Dynamic Model-Agnostic Federated Learning with Pruning and Knowledge Distillation for Maritime Predictive Maintenance

Predictive maintenance (PdM) is vital to maritime operations; however, the traditional deep learning solutions currently offered heavily depend on centralized data aggregation, which is impractical under the limited connectivity, privacy concerns, and resource constraints found in maritime vessels. Federated Learning addresses privacy by training models locally, yet most FL methods assume homogeneous client architectures and exchange full model weights, leading to heavy communication overhead and sensitivity to system heterogeneity. To overcome these challenges, we introduce FLUID, a dynamic, model-agnostic FL framework that combines client clustering, structured pruning, and student–teacher knowledge distillation. FLUID first groups vessels into resource tiers and calibrates pruning strategies on the most capable client to determine optimal sparsity levels. In subsequent FL rounds, clients exchange logits over a small reference set, decoupling global aggregation from specific model architectures. We evaluate FLUID on a real-world heavy-fuel-oil purifier dataset under realistic heterogeneous deployment. With mixed pruning across clients, FLUID achieves a global R2 of 0.9352, compared with 0.9757 for a centralized baseline. Predictive consistency also remains high for client-based data, with a mean per-client MAE of 0.02575 ± 0.0021 and a mean RMSE of 0.0419 ± 0.0036. These results demonstrate FLUID’s ability to deliver accurate, efficient, and privacy-preserving PdM in heterogeneous maritime fleets.