Case
How condition-based maintenance saved this company €90,000
$100K repair cost savings
Take full control
Reduce downtime
Improve system management
SEE HOW A LARGE MANUFACTURING FACILITY REDUCED DOWNTIME AND SAVED UP TO $100K IN REPAIR COSTS.
The customer traditionally operated with a preventive maintenance program on the mechanical assets within their plants around the world, performing mostly light preventive maintenance, such as visual checks, on a regular basis. But they wanted a solution that gave them control and full visibility of machine health and detailed insights, as well as increase their uptime and equipment effectiveness. They implemented a continuous and portable diagnostics solution as part of a pilot program designed to mitigate their challenges and reap the benefits of an automatic diagnostics system.
REDUCE DOWNTIME AND COSTS WITH INTELLIGENT MONITORING
The customer was supplied with a continuous diagnostics solution, offering real-time, 24/7 monitoring of critical compressors. Uptime is crucial for these compressors, as any downtime can result in a costly shutdown of the production line. Upon installing this new solution, sensors detected a severe malfunction. It was immediately diagnosed as a worn thrust bearing on the main drive shaft. Basic vibration sensors would not have caught this malfunction, but thanks to the early diagnosis, the customer was able to take swift action and perform an initial $7K repair, avoiding a failure that could have resulted in a replacement of the compressor, which could have cost them more than $240K.
PLAN MAINTENANCE BASED ON DATA
During the repair, further wear was spotted on one of the other bearings. Since the monitored system enables full visibility of the condition of the malfunction, the plant team decided not to repair the issue there and then. Instead, the replacement of the compressor was scheduled to take place during the next planned downtime, preventing additional repair costs of $100K. The predictive diagnostics algorithm enabled the customer to monitor the health of their most critical assets, providing them with unprecedented control of the facility. This form of predictive maintenance allows the plant to increase its uptime, keep comfort levels high and avoid unnecessary costs.