24 hours of unplanned downtime saved USD 1 Million on a single machine

downtime saved

About the Customer

A USD 568 Million Indian forging company serving in several sectors including automotive, power, oil and gas, rail, marine and aerospace, construction & mining. They manufacture a wide range of high performance, critical & safety components for the automotive sector with the capability of producing 618,750 TPA forging, 1.2 million crankshaft machining, and 0.75 million front axle machining annually.

Challenge

This large forging company in Asia faced a key problem during manufacturing, that is the lack of visibility of health of machines and its components (such as screw, bolts, motors) which results into machine breakdowns or idle time, thereby delay in delivery.

The company wanted to implement real-time monitoring system and alert system to gain control over downtime issues.

Solution

The company decided to implement IDE on its 5000 tonne press line manufacturing crankshafts.

  • IDE implementation on press line: The installation of IDE and IDAP was done successfully on TES transfer system, press ram, and motor, as a part of press line.
  • IDE specializes in high-frequency data analytics, such as tri-axial vibration and broadband acoustic spectral analysis.
  • IDE was made responsible for detecting the unusual vibration on transfer system, improper change in acceleration and deceleration; identify faulty equipment by acoustic to prevent failure.
  • All the analysis was displayed on the dashboard of IDAP which analyzes the equipment failure and generate alerts.
  • IDAP analyzed production line throughput and offered tailored visualization and intelligence report.

Action Plan and Results

Key Insights:

  • Asset Reliability: The IU solution application monitored the health and performance of various mechanical components and equipment by measuring frequency, velocity, temperature, noise level, vibration acoustic; raising alerts on anomalous performance, and thus manage asset reliability.
  • Real Time Visibility: The platform analyzes the metrics of the performance of mechanical components which helps in real time visibility.
  • Reduction in unplanned downtime: The prediction of breakdown in early failure period enhanced the productivity by reducing unplanned downtime.

Use of IDE and IDAP on press prevented the unplanned downtime, minimized breakdown maintenance costs, prevented delay in productivity, and helped in boosting efficiency of the manufacturing process.

Main Press Ram – Die Holder Screw Breakage Predicted: January 5, 2018.

The IDE detected the loosening of die holder bolts and displayed the variation in sideways and endways vibrational velocity of 5000 tonne press ram in the large forging company which manufacture crank shafts. Further, the loosening of bolts creates an additional load on motor which impacts the vibration and temperature of main motor which is another indication for the breakdown. Moreover, the platform alerted the manufacturers about potential breakdown through email and SMS. The IU solution application predicted the breakdown and saved 24 hours of unplanned downtime.

Transformation

24 hours of unplanned downtime saved USD 1 Million for a single machine

This prediction saved the single press ram from permanent breakdown and also saved cost of USD 2,146.

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