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Purpose The purpose of this paper is to propose an optimal predictive model for the short-term forecast of real-time non-stationary machine variables by combining time series prediction with adaptive algorithms to minimize the error and to improve the prediction accuracy. Design/methodology/approach The proposed model is applied for prediction of speed and controller set point of three-phase induction motor operating on closed loop speed control with AC drive and PI controller. At Stage 1, the trend of the machine variables has been extracted and added to auto-regressive moving average (ARMA) time series prediction. ARMA prediction has been carried out using different combinations of AR and MA methods in order to make prediction with less Mean Squared Error (MSE). Findings The prediction error indicates the inadequacy of the model to estimate the data characteristics, which has been resolved at the subsequent stage by cascading an adaptive least mean square finite impulse response filter to the time series model. The adaptive filter receives the predicted output including training data and iteratively adjusts its coefficients for zero error convergence. Research limitations/implications The componentized data prediction based on time series and cascade adaptive filter algorithm decomposes the non-stationary data characteristics for predictive maintenance. Evaluation of the model with different combination of time series algorithms and parameter settings of adaptive filter has been carried out to illustrate the performance of the prediction model. This prediction accuracy is compared with existing linear adaptive filter prediction using MSE as comparison index. The wide margin in the MSE values substantiates the prediction efficiency of the proposed model for machine data. Originality/value This model predicts the dynamic machine data with component decomposition at high accuracy, which enables to interpret the system response under dynamic conditions efficiently.

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