Infinite Uptime Case Studies USD 1.2 Million Saved On A Forging Press Line By Predicting Cutter Life

	USD 1.2 Million Saved On A Forging Press Line By Predicting Cutter Life Infinite Uptime

USD 1.2 Million Saved On A Forging Press Line By Predicting Cutter Life

Infinite Uptime

Technology Category	Analytics & Modeling - Predictive Analytics Functional Applications - Remote Monitoring & Control Systems Sensors - Acoustic Sensors Sensors - Temperature Sensors Sensors - Vibration Sensors
Applicable Industries	Equipment & Machinery
Applicable Functions	Maintenance
Use Cases	Predictive Maintenance
Challenge	The major press line in the company has a circular saw machine which cuts metal rods with precision in predefined lengths for further heating in the furnace. The cut pieces are then fed to the forging line to make automotive components. The length and perpendicularity of the cut pieces are crucial to obtain a good quality forging. It was observed that circular saw failed to maintain the precise length and perpendicularity while cutting the metal rods leading to heavy rejections. This was a serious concern and routine preventive maintenance was unable to overcome it. Read More
About Customer	A world’s leading forging Company headquartered in Pune, having a global workforce of 10 Thousand. A major contributor to the automotive industry with more than five decades of expertise. Read More
Customer Name	Undisclosed Read More
Solution	INDUSTRIAL DATA ENABLER installed on the gearbox near the Circular Saw Cutter monitored the tri-axial vibrations, temperature, and acoustics in real-time. Its edge technology analyzed the vibration data and notified the production and maintenance personnel the instant the vibrations exceeded a set limit. The IDE captured the vibrations from the gearbox of the circular saw cutter. Read More Log in to view content
Data Collected	Vibration Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Predictive Analytics

Functional Applications - Remote Monitoring & Control Systems

Sensors - Acoustic Sensors

Sensors - Temperature Sensors

Sensors - Vibration Sensors

Applicable Industries

Equipment & Machinery

Applicable Functions

Maintenance

Use Cases

Predictive Maintenance

Challenge

The major press line in the company has a circular saw machine which cuts metal rods with precision in predefined lengths for further heating in the furnace. The cut pieces are then fed to the forging line to make automotive components. The length and perpendicularity of the cut pieces are crucial to obtain a good quality forging.

It was observed that circular saw failed to maintain the precise length and perpendicularity while cutting the metal rods leading to heavy rejections. This was a serious concern and routine preventive maintenance was unable to overcome it.

About Customer

A world’s leading forging Company headquartered in Pune, having a global workforce of 10 Thousand. A major contributor to the automotive industry with more than five decades of expertise.

Customer Name

Undisclosed

Solution

INDUSTRIAL DATA ENABLER installed on the gearbox near the Circular Saw Cutter monitored the tri-axial vibrations, temperature, and acoustics in real-time. Its edge technology analyzed the vibration data and notified the production and maintenance personnel the instant the vibrations exceeded a set limit. The IDE captured the vibrations from the gearbox of the circular saw cutter.

Data Collected

Vibration

Impact #1	[Efficiency Improvement - Asset Monitoring] The system can generate the vibration plot of the cutter and when it exceeded the set limit. Alarms are raised through email and SMS.

Impact #1

[Efficiency Improvement - Asset Monitoring]

The system can generate the vibration plot of the cutter and when it exceeded the set limit. Alarms are raised through email and SMS.

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Overview

USD 1.2 Million Saved On A Forging Press Line By Predicting Cutter Life

Operational Impact