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Case Studies

Prediction of Press Breakdown

The Issue

  • A diversified automotive manufacturing company in India faced repetitive erratic mechanical breakdown on their presses during continuous production resulting in unplanned downtime and issues in product delivery schedules

The Resolution

  • Detection of unusual vibrations in the lateral axis of a 1000T press 4 hours before breakage
  • Prediction of bolt breakage due to bolt wear-out and failure saved almost 10 hours of downtime per event predicted

Other Value Addition

  • Cycle time optimization by studying the motions of different moving components of the machine
  • Detection of unusual vibrations on transfer system to prevent a failure resulting in higher asset reliability
  • Detection of improper change in acceleration and deceleration in the hydraulic press indicating improper functioning of proportional valve
10
hours of unpredicted downtime saved per month per machine

Pump and Motor Monitoring

The Issue

  • The valve manufacturer in Tokyo faced issues in misalignment and worn bearings that lead to excessive vibration, and ultimately, pump and motor failures leading to major production losses

The Resolution

  • Identification and prediction of faulty equipment by acoustic, temperature and vibration monitoring of pumps and motors
  • Achievement of 50% lower breakdown due to a combination of FFT and predictive analytics
  • Prediction of misalignment, looseness, shaft eccentricity, and wear out through high frequency vibrations analysis
INDUSTRIAL DATA ANALYTICS PLATFORM
50
% reduction in unplanned breakdown

Prediction of Roll Breakage

The Issue

  • The large conglomerate automotive manufacturing company based in India faced  recurring breakage in its spline rolling machines which impacted the overall production efficiency as well as unreliable product quality

The Resolution

  • IDEs installed on roll predicted the wear out in advance and notified the manufacturer for tool replacement, saved the unplanned downtime and improved the product quality reliability
  • The deterioration on roll due to over vibration was detected and displayed in the form of pattern tracking visualization
Predictive intelligence can improve operative KPIS

Prediction of TES transfer system clamp and conveyor hanger breakdown

The Issue

  • A large forging company in Asia faced erratic breakdown in its TES transfer system clamp during mass production resulting in major line stoppages, lower-than-anticipated production  output and low production efficiency.

The Resolution

  • 13 IDEs were installed each on a 5500 ton hot forging press and 5000 ton hot forging press
  • TES transfer system clamp: Breakdown reduced from 18% to 1%
  • Predictive maintenance protocol established and every predictive alert is now responded to within 2 hours
  • Conveyor Hanger: Identification of conveyor drive hanger issues are now detected and action is taken before breakdown, protocol is changed
  • Spares: Spares inventory is reduced by 30% due to higher reliability of equipment and assets
25
% of more production potential unlocked per year towards direct profit

OEE Improvement

The Issue

  • An automotive manufacturing company wanted to improve its OEE due to a surge in customer orders and not enough time to purchase new machines and expand capacity for those orders

The Resolution

  • Identification of hidden losses by studying the production characteristics of a machine gave insights into the scope for improvement
  • Achievement of record production within 2 months due to a combination of operative and predictive analytics
  • Moving from Preventive Maintenance to Predictive and Proactive Maintenance can reduce breakdown by 90% and improved OEE to record levels
IDAP Analytics
90
% Breakdown reduced
30
OEE improved over 6 months

Prediction of die holder screw breakage in Main Press Ram

The Issue

  • A large forging company in Asia wanted to reduce its unplanned downtime due to breakage of die holder screw bolt in its Main Press Ram

The Resolution

  • Detection of the loosening of die holder bolts and identification of the variation in sideways and endways vibrational velocity of the 5000 ton press ram
  • 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, also detected and correlated for the same anomaly prediction
  • IDAP platform alerted the manufacturers about potential breakdown through email and SMS and a major machine breakdown was saved resulting in huge savings for the customer 
Predicted impending breakdown 8 hours in advance and saved 24 hours of unplanned downtime per event

Prediction Anomalies In Advance And Prevent Poor Quality Production

The Issue

  • The large auto supplier in India faced repeating issues of bearing failure in a cylindrical grinding machine which caused heavy breakdown during the manufacturing process

The Resolution

  • Downtime due to breakdown maintenance in 6 months (from SAP system)= 46 hours (Line-11, new Grinding M/c)
  • Causes of breakdown time that were predicted and prevented: belt slippage, pulley damage, motor wear-out, bearing wear-out
  • Approximate ratio of breakdown time that can be prevented on all machines per year through predictive analytics = 60% of breakdown time
28
Unlocking a potential of 28% more output per year towards direct profit

Prediction of unstable velocities in a gearbox

The Issue

  • The diversified conglomerate paper manufacturing company in India faced gearbox  failure which resulted into unreliable product quality and unexpected line stoppages

The Resolution

  • IDE detected very irregular FFT spectrum for the Z axis for the gearbox
  • IDAP displays anomalous harmonics in the 2x and 3x regions (first even and first odd harmonics) and unusually high 1x –indicating the onset of misalignment
  • Very large peak in the frequency spectrum for the dominant frequency indicating a very clear misalignment and immediate need for dynamic balancing
  • Dynamic balancing of the system resolved the issue and erratic breakdowns were eliminated
Prediction of unstable velocities in all 3 axes indicating unstable equipment

Prediction of unstable velocities in a gearbox

The Issue

  • The large refinery of India faced erratic failure of pumps which resulted into lower productivity.

The Resolution

  • IDE detected very irregular FFT spectrum for the Z axis for Pump
  • Anomalous harmonics in the 2x, 3x and 4x regions (first two even and first odd harmonics) –indicating the onset of misalignment or looseness
  • No large peak in the frequency spectrum for the dominant frequency indicating a clear misalignment or eccentricity in the system in the Z axis about the X-Y plane
  • Fixing the pump assembly on-site resolved the issue completely
  • Other Value Additions / Insights:
  • The pump failure resulted in varying temperature profiles in which a continuous repeatable pattern was observed
  • Sharp peak / increase in temperature on 28 August which was tagged as anomalous by the system as correlated with the vibration spectrum of the pump at the same time
  • Average temperature of around 50 degrees but high standard deviation indicating a loading and unloading pattern or varying load patterns
Continuous Data Monitoring and Anomaly Detection