Case Study: Loss Prevention through Fault Prediction Monitoring of Machinery Equipment (Bearing Vibration)
Achieved predictive monitoring of production line equipment failures. Detected inner ring damage in bearings through vibration frequency analysis, preventing equipment downtime and avoiding losses of up to 70 million yen.
A case study on preventing machinery failures using vibration sensors in a film production line. There was a problem where the production line could incur losses of up to 70 million yen if machinery failures caused a halt. Therefore, we monitored bearing vibrations as precursors to failures for the extruder and stretching machine, enabling vibration frequency analysis due to excessive danger, and established a system that allows for maintenance before machinery failures occur.
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basic information
Related: Rotating Machinery Fault Prediction Monitoring System Wiserot The Wiserot rotating machinery fault prediction monitoring system is a system that enables preventive maintenance for rotating machinery and motor-related equipment. By regularly measuring the vibrations of rotating machinery operating on production lines and as critical equipment, it contributes to the early detection of abnormal signs through trend monitoring, allowing for the planning of appropriate preventive maintenance and reduction of production loss costs.
Applications/Examples of results
**Case Study: Avoiding Losses through Fault Prediction Monitoring of Machinery Equipment (Bearing Vibration)** **Implementing Company:** Chemical Industry **Implemented Product:** Rotating Machinery Fault Prediction Monitoring System Wiserot **Target Equipment:** Film Production Line (Extruder, Stretching Machine) **System Configuration:** Wiserot vibration sensors were installed on the extruder and stretching machine, monitoring machine vibrations and bearing vibrations for fault predictions via monitoring software (PC) over Ethernet. **Challenges Before Implementation:** In the production line, if one piece of machinery fails, the entire line comes to a halt. It may take 3 to 7 days to restore the machinery, leading to total losses ranging from 30 million to 70 million yen, depending on production volume. **Implementation Effects:** Due to excessive bearing vibration, a frequency analysis was conducted, resulting in the detection of inner ring damage in the bearing. Upon performing maintenance, scratches were confirmed on the bearing's inner ring. The customer replaced the bearing and continued normal operations, successfully avoiding stoppage and losses in the film production line.
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Motor preventive maintenance and rotating machinery failure prediction monitoring system
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Providing solutions for various plants and factories such as food, chemicals, oil and gas pipelines, paper and pulp, and cleaning facilities. Our measurement and control systems have over 40 years of history since the launch of the first distributed control system in 1975. Based on our track record, we propose systems and solutions to support the latest technologies, IoT utilization, and the development of smart factories. - Steam generation heat pumps / waste heat utilization / visualization of thermal energy - Clamp-on steam flow meters / flow meters / flow sensors / thermal balance analysis - Industrial furnaces / electric furnaces / high-frequency induction furnaces / IGBT power supplies - Gas analyzers / gas measurement devices / gas analysis sensors - Predictive maintenance / anomaly detection maintenance / preventive maintenance / maintenance and prevention systems / smart security - Smart factory - MES / DCS / SCADA / edge controllers - EMS / energy management systems / visualization of energy - Smart glasses / remote work support systems - Multivariate analysis / MSPC - Engineering tools
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