ENERGY · WIND

Finding every suspect blade: failure containment for a wind-turbine OEM

When a blade defect appears in the field, the manufacturer must decide which blades to inspect. Inspecting everything from a plant is slow and costly; inspecting too few leaves defects in service. Wexa linked manufacturing, field service and customer contracts in one graph and let an agent find the exact cohort.

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inspections needed (graph cohort vs PLM-only)
recall: no defective blade left in service
less inspection cost at an assumed $1.1M per blade
node and relationship types across 3 systems

CLIENT: Global wind-turbine manufacturer
REGION: Global
WHEN: 2026
ENGAGEMENT: Solution build
WEXA COMPONENTS: Wexa · custom ontology · context graph · cohort agent

01Case 13

The challenge

Defects travel through adhesive lots, plant transfers and people, not just through one plant
PLM, field-service and CRM data live in separate systems
Customer contracts carry tight serial-defect notice periods (as short as 48 hours)

What Wexa built

Ontology spanning PLM (blades, adhesive lots, plants), field service (inspections, inspectors) and CRM (customers, contracts, notice terms)
Cohort agent that walks provenance only and never reads the defect label
Comparison against PLM-only and plant-sweep containment strategies
Customer-notice view ranking affected contracts by notice deadline

02Case 13

How it runs on Wexa

FigureHow this use case runs on Wexa: client systems connected, ontology discovered, context graph in the Wexa memory layer, agents and process flows, and governance. Highlighted components are central to this use case.

03Case 13

Results

Measure	Before / without Wexa	With Wexa
Blades inspected per containment event	24 blades	6 blades
Annual cost of the process	$26.4M	$6.6M
Time to implement the AI solution	6 months	4 weeks
AI build cost (one-time)	$480K	$30K
AI operating cost per year (models, infrastructure, upkeep, platform)	$312K	$166K
Total AI cost in year 1	$792K	$195K

With Wexa

net annual value to the client after Wexa's own operating cost

faster to implement

lower AI operating cost

less AI spend in year 1

Validation test: the graph cohort needed 6 inspections and found every defective blade; PLM-only needed 24; a plant sweep needed 18 and missed 2
The missed blades were reached only through an inter-plant adhesive-lot transfer and an inspector on secondment, relationships that exist only in the graph