AUTOMOTIVE INDUSTRY

The automotive industry is one of the world's most dynamic and competitive industries, being under continuous pressure to improve performance in a highly competitive, cost-sensitive environment. Though every automotive manufacturing facility is well equipped with forging press, drilling machines, spot-welding equipment, CNC, etc. all these equipment are powered by motors. Bearings and gearboxes also play a vital role in the facility.

The fundamental purpose of Maintenance in any business is to provide the required capacity for production at lower costs. Every manufacturing facility has rotating machinery and equipment. Pumps, motors, gearboxes, machine tools and process equipment all incorporate shafts, couplings and bearings. Adopting a vibration - monitoring-based Predictive maintenance is the best way to protect the equipment and the workforce, especially if it is required to operate 7. The use of cutting-edge technology and quickly installable IDE vEdge patented and Made in India, delivers actionable diagnostics and repair recommendations along with the insights to drive effective maintenance and reliability programs.

Why Predictive Maintenance is necessary in Automotive Industry?

01. Zero downtime

37 % production time on a critical asset conserved

02. 46% deliverables facilitated

80% of common problems predicted at 20% Cost

03. Maintains high-level availability in the production lines

100% Proactive monitoring of smaller machines used for the production of larger components

04. 40% Reduction of R&R costs

98% accuracy in determining health of operating equipment.

automotive manufacturing facility
predictive maintenance

Case Studies

Automotive/Motor
Automotive/Motor

Automotive forging unit implements real-time monitoring system; ensures uninterruptable stamping of auto-components.

Automotive/Motor
Automotive/Motor

Detection of crack on 5000 Tons Pitman on forging Press; saves USD 5,00,000.

Automotive/Motor
Automotive/Motor

Plug and Play Vibration Sensor saves 100HP Motor; conserving USD 40,000 per hour.

Automotive/Gearbox
Automotive/Gearbox

Global Award-winning Sensor prevents failure of gearbox and cutter; saves USD 120,00,000.

Automotive/Motor
Automotive/Motor

Made-in-India Motor Monitoring tool saves industrial motor; ensures timely delivery of ~1,50,000 components.

Automotive/Motor
Automotive/Motor

IP68 Certified Vibration monitoring sensor predicted major motor failure; safeguarded USD 700,000.

Automotive/Motor
Automotive/Motor

Predictive Maintenance Solution saves HDC 40 Ton Motor; conserves production of USD 72,000.

Automotive/Fan
Automotive/Fan

Smart Vibration Monitoring Solution predicts unbalance in Exhaust Fan in the Paint Shop saving USD 45,000.

Automotive/Motor
Automotive/Motor

Remote monitoring of motor assures 24 X7 production; benefits USD 40,000 per hour.

Automotive/Bearing
Automotive/Bearing

Early detection of bearing failure saves USD 36000 in automotive transmission system.

Automotive/Bearing
Automotive/Bearing

Bearing monitoring improves 10% efficiency of equipment; profits OEM by USD 20,000.

Automotive/Motor
Automotive/Motor

IDE vEdge saves 1001T Press Motor; avoids production loss of USD 20,000.

Automotive/Motor
Automotive/Motor

USD 30,000 saved on 4000T Press in an automotive component manufacturing plant.

Automotive/Motor
Automotive/Motor

24 Hours of Unplanned Downtime Saved USD 1 Million for a Single Machine in Manufacturing Facility

Automotive/Spindle
Automotive/Spindle

Spindle monitoring provides insights into Root Cause Analysis for spindle failure saves USD 58 Thousand per hour

Automotive/Motor
Automotive/Motor

Spindle monitoring provides insights into Root Cause Analysis for spindle failure saves USD 58 Thousand per hour

Automotive/Motor
Automotive/Motor

Instantly deployable condition monitoring sensor saves USD 45,000 and ensures safety in Paint Shop.

Automotive/Spindle
Automotive/Spindle

Real-time Vibration Monitoring System predicts spindle-overload; prevents bearing failure; conserves USD 10,000.

Automotive/Motor
Automotive/Motor

Cost-effective Vibration Monitoring System saves Motor and fan; avoids loss of USD 38,000.

Automotive/Bearing
Automotive/Bearing

Prediction of failure in Draw bench Assembly saves USD 8000 in piping plant.

Automotive/Motor
Automotive/Motor

USD 2000 per hour saved on fin pass mill in piping plant.

Automotive/Gearbox
Automotive/Gearbox

Zero downtime for material handling saves USD 1,500 per hour in a tube plant.

Automotive/Motor
Automotive/Motor

Plug and Play, Predictive Maintenance system prevents failure of Motor-driven Fan; saves USD 45,000.

Automotive/Motor
Automotive/Motor

Plug and Play, Predictive Maintenance system prevents failure of Motor-driven Fan; saves USD 45,000.

Automotive/Bearing
Automotive/Bearing

Zero interruptions ensures production target 8 hours in advance; confirms USD 40,000.

Automotive/Motor
Automotive/Motor

End-to-end Vibration monitoring system predicts Dowel Milling Machine failure; saves USD 5,000.

Automotive/Motor
Automotive/Motor

End-to-end Vibration monitoring system predicts Dowel Milling Machine failure; saves USD 5,000.

Automotive/Bearing
Automotive/Bearing

Automotive Forging Components Manufacturer saves USD 17,000 using predictive maintenance solution.

Automotive/Motor
Automotive/Motor

SMART condition monitoring saves USD 30,000 by predicting erratic failure of 4000T Press

Automotive/Bearing
Automotive/Bearing

Award-winning Vibration monitoring sensor prevents Spindle failure of Milling machine; safeguards USD 12,000

Automotive/Spindle
Automotive/Spindle

Advance-computing technology predicts spindle-overload; prevents failure of Gear-Hobbing Machine; and saves USD 10,000.

Automotive/Motor
Automotive/Motor

Failure Of Clutch Brake Assembly Predicted; Saves USD 7800 In A Trimming Press

Automotive/Bearing
Automotive/Bearing

Predictive maintenance recommended by Vibration monitoring gadget saves USD 15,000 in Forging Press

Automotive/Motor
Automotive/Motor

Predictive maintenance recommended by Vibration monitoring gadget saves USD 15,000 in Forging Press

Automotive/Motor
Automotive/Motor

Vibration Monitoring System predicts Trimming machine failure; reduces Maintenance costs by USD 10,000.

Automotive/Motor
Automotive/Motor

Plug and Play Condition Monitoring Tool safeguards USD 12,000 by predicting 50KW motor breakdown.

Automotive/Bearing
Automotive/Bearing

Edge Computing based vibration monitoring sensor predicted spindle-overload and failure; saved USD 5,000

Automotive/Bearing
Automotive/Bearing

USD 10,000 saved on a M707CNC Hobbing machine in Running Gear manufacturing Plant.

Automotive/Bearing
Automotive/Bearing

Prediction of Gear Hobbing machine failure saves USD 10,000 in Automotive Plant.

Automotive/Bearing
Automotive/Bearing

Monitoring motor -bearing of shaping machine; ensures its reliability; achieves target of USD 10,000

Automotive/Bearing
Automotive/Bearing

Unexpected bearing Failure on Grinding Machine prevented; downtime of 12 hours conserved.

Automotive/Motor
Automotive/Motor

Predictive Maintenance end-to-end Solution remotely supervised hot forging press and significantly prevented its breakdown.

Automotive/Bearing
Automotive/Bearing

Indian-make vibration Monitoring sensor overcomes unplanned downtime; Saves high repair and replacement costs.

Automotive/Motor
Automotive/Motor

Monitoring bearing of Shaping machine; ensures its reliability; achieves target of USD 10,000.

Automotive/Motor
Automotive/Motor

vEdge pinpoints tool-change in Stamping Press; recommends safety measures to enhance Motor-life.

Automotive/Motor
Automotive/Motor

Vibration Monitoring System offers quick-decision making with its insights obtained from bearing-monitoring.

Automotive/Motor
Automotive/Motor

Plug and Play vEdge predicts anomaly in motor-powered blower-fan operations; assures safety of the workforce

Automotive/Bearing
Automotive/Bearing

Cutting-edge Vibration Monitoring sensor overcomes unplanned downtime; saves repair and replacement costs.

Automotive/Motor
Automotive/Motor

Raising early warnings of critical Motor-failure conserves ~50 downtime-hours in Automotive Plant.

Testimonials

We have tested IDE vEdge from last one month and got the detailed reports along with FFT spectrum, this system seems to be effectively triggering the alarms of impending failure as promised by Infinite Uptime. It is very useful and now we are planning to fix this in our multi-spindle Gang head gearbox.

Mr. E. N Patro, Maintenance Executive - Honda Motorcycle & Scooter India Pvt. Ltd., Karnataka

Infinite Uptime has measured high on our expectations of quality, flexibility, and in-depth industry knowledge and has continuously raised the bar. I must say vEdge is an outstanding product, I'll recommend vEdge as an optimum cost solution.

Mr. Keshav Prasanna, Senior Vice President - Reliance Industries Limited

We worked carefully with all our equipment that helped us for our living. We maintained them as and when required but still faced production losses and high downtime. Thank you Infinite Uptime for installing the IDE, to monitor gearboxes, motors, bearings and other critical mechanical rotating parts at real-time. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

Mr. Sajo Paul, Plant Manager & Development Officer - TVS Motors

Thanks to Infinite Uptime for providing insights into our critical equipment. The plug and play real time monitoring IOT 4.0 solution, avoided unexpected breakdowns and detected large savings capabilities. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

Mr. Bhide/Mokashi, Maintenance Manager - Bharat Forge

As promised by Infinite Uptime, the IDE sensor provided valuable data to find the root cause of abnormal vibration of the helical gearbox. With scheduled maintenance, vibration levels are normal now. We found the IDE sensor useful to avoid the breakdown.

Mr. Shahikant Bhujbal, Sr. Manager - Integrated Electrical - Tata Steel Tarapur

Thank You very much to everyone for installing the IU devices, integrating them with PLC in optimal time. We are now able to have an insight into tool life monitoring and can schedule predictive maintenance for the machines.
We look forward to continue work with you. We appreciate your dedicated time and efforts invested to achieve our goals.

Mr. Rahul Nalawade, Maintenance & Automation Head - Hirschvogel Components India Ltd.

We are monitoring our state of art machines with Infinite Uptime’s vEdge. It is providing insights into our critical equipment thereby transforming our maintenance to predictive. The plug and play real-time industrial 4.0 vEdge help to avoid unexpected downtime and saves cost. The triggering of alarms with notifications on our mobiles has added an instantaneous rectification process increasing machine availability.

Imran Hidayath, CEO - Hidayath Group of Industries, UAE

Trusted By Leading Industries Around The World

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SHRIRAM PISTONS & RINGS LTD
SKH
TATA Motors
TOYOTA
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EICHER
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