How To Improve KPI Of Equipment In a Manufacturing Facility?

Almost every equipment in manufacturing is to support the production of the product. The equipment has a value only when it produces more than what it consumes. To sustain its value, the equipment should perform consistently, maintain the product quality and fulfill the needs of the customer. Thus, in any manufacturing facility, higher the Key Performance Indicators (KPI), more valued is the equipment.


Why are the KPI important?

The KPI for any equipment in a manufacturing facility is associated with quality, availability, operating costs, Overall Equipment Effectiveness (OEE), reliability and safety (of the equipment and the operator).  KPI identifies the gaps between the existing  performance and expected performance and provides visibility of progress towards minimizing the gaps. Measuring KPI in a manufacturing unit helps to estimate the maintenance budget. KPI assists to calculate the remaining useful life of the equipment. KPIs are extremely essential for the success of the plant hence monitoring them and striving to improve them is vital. The KPI’s evaluate the potency of the condition monitoring team and plan for the equipment maintenance that directly affects the machinery or its performance and the overall OPEX.

What is KPI monitoring for a motor? 

About 90% of the capital assets in a manufacturing plant comprise of motors. They consume more than 50% of the energy used in the manufacturing process. Hence monitoring their operational efficiency, tracking the energy expenses incurred on them and reducing the unscheduled downtime is necessary. Preserving the history of motor and running-hours of the motor, load-duration curves, Mean Time Between Failures (MTBF), frequency of unscheduled outages helps in determining KPI for a motor. Due consideration to motor-application, its manufacturing details, bearing changes (if any) and drives connected to the motor play a significant role in determining the KPI for a motor. Higher the production KPI , higher the equipment uptime, lower the breakdown. This not only saves the maintenance costs but also enhances the longevity of the equipment. In other words, vibration monitoring of the motor substantially maintains the KPI of the motor.

How to monitor KPI for a pump? 

It is extremely complicated to monitor the KPI for a pump as merely inspecting the flow, pressure, and temperature may not provide a complete view of a pump’s performance. Compatibility between the pump and the drive increases the pumping, optimizes specific energy and reduces the operational cost of the pump. Thus, reduced maintenance cost, the sensitivity of the pump to the changes in the processes, higher reliability, and better efficiency in its operation form the KPI for a pump. The load on the pump is directly proportional to the rated current. Care must be taken to ensure that this proportion is asserted to achieve the expected KPI. Lower the MTBF higher is the KPI. Needless to say, condition monitoring of pump highlights the manufacturing and operational KPI  for a pump. 

Tips for Monitoring the KPI for bearings

Decrease in the time required to complete a product, increase in the uptime, accuracy in calibration, installation of bearings within the prescribed tolerance values, precision in lubrication (handling, filtering, free of contamination, humidity, and application), correctness in following the alignment specifications and periodic testing for contamination of the lubricant (like oil, grease) are the critical parameters to be considered in monitoring the bearings. As bearings are the heart of any equipment, an inspection of bearing for corrosion, deterioration, odd noises (such as light clicking, squealing), along with observing the vibrations and trending them is very important. Finally ensuring the temperature of the bearing between 900C to 1000 C and an audio-visual review is vital for the smooth operation of the bearings. An ultra-sound test also provides insights into the functioning of bearing and enhances its KPI. 

KPI Monitoring of Gears made easy

Gearbox or toothed wheel is a peripheral system in any manufacturing plant. Real-time monitoring of the gear so that it achieves the desired speed is vital. Failure of gearbox results in the damage of other components increases the acoustic signals and consequently causes a breakdown in the assembly. Hence the gear quality, load capacity, gear life, streamlining of gear operations, gear dynamics, vibration and noise, desired tolerable spacing in the thickness and form of gear-teeth should be closely and consistently examined to maintain its KPI. Lubrication of the gears concerning contamination, viscosity, presence of water particles and ferrography plays a crucial role to maintain the gear profile and prevent it from damages. Further upholding the temperature of the gearbox lubrication within the ordained limit also enhances the KPI. 


Infinite Uptime’s Industrial Data Enabler (IDE) is a Predictive Maintenance tool to remotely monitor real-time vibrations, acoustics, and temperature of any rotating equipment and predict failure.  With its edge-computing technology, it can potentially ensure the maximum uptime of the equipment and thus digitize any critical equipment. Digitization keeps a track of material and history of the equipment, builds a digital network architecture on the shop floor, ensures safety and increases the accessibility to monitor the status of equipment; subsequently yielding higher levels of KPI. 


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