Nearline-PM for Pharmaceuticals
Wireless Network Vibration Sensor System "NearLine-PM" [Enables proactive measures before failures by predicting equipment abnormalities]
Early detection of equipment abnormalities in pharmaceutical processes with vibration sensors. Supporting planned maintenance.
In the pharmaceutical industry, process management emphasizes the importance of stable operation of manufacturing equipment. Equipment failures can lead to production stoppages and quality issues, potentially resulting in significant losses. Particularly in drug manufacturing, abnormalities in equipment directly affect product quality, necessitating early detection of anomalies and appropriate responses. Nearline-PM enables early detection of equipment anomalies through vibration diagnostics using vibration sensors, facilitating planned maintenance. 【Use Cases】 - Monitoring of pumps, compressors, fans, and other equipment on the production line - Remote monitoring of equipment vibration data - Early detection of equipment anomalies to reduce downtime 【Benefits of Implementation】 - Reduces the risk of equipment failure and achieves stable operation - Cuts maintenance costs through planned maintenance - Contributes to maintaining product quality
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【Features】 - Utilizes battery-operated wireless sensors, eliminating the need for wiring work. - Allows for near-continuous monitoring with automatic measurements once a day as standard; measurement frequency can be set as desired. - Can be retrofitted, making it suitable for small-scale starts. - Supports high frequencies (17kHz) to detect initial abnormalities in bearings. - Despite being a compact sensor, it has a long battery life of approximately 5 years. - Enables easy operation and diagnostics through a dedicated app. - Technical support provided by our "Certified Vibration Diagnosis Professionals*." *ISO 18436-2 compliant, Machinery Condition Monitoring Diagnostic Technicians (Vibration) 【Our Strengths】 Asahi Kasei Engineering Corporation offers consistent engineering services from design and construction to maintenance. We conduct design, procurement, and construction (EPC) with maintenance in mind and propose appropriate maintenance based on design data. Additionally, we can propose information systems that not only focus on maintenance but also consider production efficiency and reduction of production losses. We are developing diagnostic equipment for facilities utilizing digital technology. Our engineers, who hold ISO 18436-compliant vibration diagnosis qualifications, not only provide information on vibration sensors but also apply their expertise to address the critical points of equipment.
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【Implementation Results】 We have implemented our solutions in over 300 facilities across various industries, including chemicals, power, automotive, steel, semiconductors, paper, food, shipbuilding, and maritime. 【Challenges and Background Before Implementation】 We have implemented our solutions for customers facing the following challenges due to sudden unexpected failures of rotating equipment (motors, pumps, fans, etc.), which support the production site: - Difficulty in predicting unexpected failures - Dependence on specific personnel for maintenance tasks - Increase in inspection workload - Difficulty in introducing wired sensors (installation, cost) - Significant impact from sudden equipment shutdowns 【Implementation Effects】 - Trend monitoring has made it possible to predict unexpected equipment failures - Quantitative management through vibration data has standardized the judgment of equipment normality/abnormality - The automatic measurement system has reduced inspection workload, contributing to increased productivity - The small, wireless sensors allowed for a small-scale start in installation - High-frequency measurements have enabled the detection of initial abnormalities in bearings, allowing for planned maintenance responses *For more details, please download the PDF document or feel free to contact us.*
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Asahi Kasei Engineering Corporation is a company that conducts design, procurement, and construction (EPC) with an eye toward maintenance, and also proposes appropriate maintenance based on design data. In addition to maintenance, it is also possible to propose information systems that consider production efficiency and production losses. In terms of maintenance, we are developing equipment diagnostic devices that utilize digital technology.
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