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CONDITION MONITORING
TURBINE SUPERVISORY GUIDE IS FREE TO DOWNLOAD
200-YEAR-OLD MANUFACTURER TURNS TO SMART TECHNOLOGY TO DRIVE EFFICIENCY
Cast-nylon and plastic components manufacturer Westley Plastics has improved cycle times and achieved more consistent and efficient 24/7 production after adopting smart technology, which has given the company greater visibility of its manufacturing process. Westley Plastics is a family-run business that specialises in taking engineering plastic products from concept and design to final manufacture, utilising its on-site design, casting and CNC machining facilities. It works across several heavy industrial sectors including construction, defence, automotive, rail and steel. The company operates 24 hours a day, but it was not evident whether machine utilisation and productivity were consistent throughout any 24-hour period. It was agreed that greater visibility of the shop floor through machine monitoring would enable them to identify capacity and cycle times and help to focus the workforce on the processes that required and benefited most from their skills. FourJaw’s manufacturing analytics platform, which works on machines of all types and ages, enabled the business to identify machine downtimes and understand the reasons behind the stoppages. Machine monitoring has also identified and improved cycle times. The team had previously discussed running two machines at the same time but did not think it could be done. However, the data from FourJaw revealed which machines could be run together – improving efficiency, productivity and job profitability. Tom Westley, operations director says: “The information that the FourJaw platform provides
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Midlands-based manufacturer that can trace its roots back more than 200 years is using Industry 4.0 machine monitoring software from FourJaw to drive efficiency.
has resulted in some very positive changes for the business, including the introduction of new production processes, improvements to the factory layout, and improved cycle times by creating new jigs, reducing on-job operations of big jobs by 50 per cent. “We now have a clear and informed picture of the factory floor including accurate cycle times and utilisation by shift. The factory is now more efficient and productive with its resources which is evidenced by the increased utilisation of machines running 24 hours during the week, which has improved so much that fewer shifts need to run over the weekend, saving the business money on staffing, energy and other operating costs.” Westley Plastics’ smart factory strategy will include installing FourJaw machine monitoring to every machine that it adds to its manufacturing operations as it grows. Oliver Pogmore, head of business development at FourJaw, adds: “Our MachineLink IIoT device can be easily and quickly self-installed on any manufacturing machine, regardless of brand, type or age, which makes it perfect for small and medium- sized businesses who’d prefer a low-cost, no-fuss ‘plug-and-play’ solution. By monitoring and analysing machine data, FourJaw enables manufacturers to make machines run productively and profitably. This is certainly the case for Westley Plastics. “It’s always been important to get the most from your assets, but we are seeing a big uplift in manufacturers turning to smart technologies to ensure their machines are as productive and efficient as possible. Enabling them to offset some of the economic and inflationary pressures faced”
FourJaw
fourjaw.com
22 JANUARY/FEBRUARY 2023 | INDUSTRIAL COMPLIANCE
f you are involved in the supervision of turbines and other rotating machinery the recent publication of a free-to- download Turbine Supervisory Guide from condition monitoring and protection specialists Sensonics will prove invaluable. This latest guide follows the very successful release of two previous publications from Sensonics covering Vibration Monitoring and more recently focussing on Seismic Monitoring.
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The supervision of turbines and other similar machinery is critical in power plants to ensure their smooth and trouble-free operation. Many serious faults, which can cause the immediate shutdown of equipment and significant loss of income, can occur as a result of excessive vibration.
When a mechanical problem, such as a cracked rotor first emerges, it can often be detected and rectified with a planned safe shutdown before severe or even catastrophic damage occurs. This is where this comprehensive 21 page guide really helps as it outlines the importance of effective vibration, position and shaft speed monitoring as part of a turbine supervisory strategy in a clear and concise way.
The six part guide covers all the important aspects of Steam Turbine monitoring such as; Absolute Casing Vibration, Eccentricity and Relative Shaft Vibration, Rotor Differential Expansion and Shaft Position, Rotor Speed, Overspeed and Zero Speed, Casing and Cylinder Expansion, Valve Position and finally, why it pays to work with a company like Sensonics who offer over 50 years of experience in Condition Monitoring.
Sensonics
www.sensonics.co.uk
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