A Replay-Based Big Data Framework for Predictive Maintenance in Industrial IoT

The rapid growth of Industrial IoT (IIoT) has led to large volumes of sensor data, increasing the need for scalable and data-driven maintenance solutions. This paper presents a replay-based streaming framework for predictive maintenance that integrates Apache Kafka for data ingestion, Apache Spark Streaming for distributed processing, and an LSTM-based model for fault prediction. The NASA CMAPSS FD001 dataset is used in a controlled streaming simulation to evaluate the feasibility of processing multivariate degradation data under different workload levels. To reduce data leakage, engine units are split before sliding-window sequence construction. Experimental results show that the LSTM model achieves 90.4% accuracy, 89.2% precision, 87.6% recall, and an F1-score of 88.4% on the test set. Under the controlled replay conditions, the observed post-Spark prediction-stage latency remained below 600 ms across the evaluated workload levels. Since the Kafka and Spark timing components and the original micro-batch interval were not retained separately, these measurements should not be interpreted as end-to-end pipeline latency. The results demonstrate the feasibility of integrating stream-processing technologies with deep learning for predictive maintenance, while full end-to-end latency and horizontal scalability remain subjects for future evaluation.