COVER STORY u Schaeffler Where the smart money is
Condition-based monitoring is the most effective way to ensure equipment uptime within process-driven environments, yet it has traditionally only been used on critical machinery due to high implementation costs. Sally Sillis, Technology Centre Manager at Schaeffler, explains why that no longer has to be the case.
E
quipment failure is the single largest source of lost production in manufacturing and other process-based
environments. The associated costs vary widely depending upon industry but according to The International Society of Automation, almost every plant loses at least five per cent of its production due to downtime, with some losing up to 20 per cent and the cost to the global processing industry alone is estimated to be in the region of $20bn.
MONEY MATTERS Many organisations implement a planned preventive maintenance strategy – replacing auxiliary equipment on a time-based schedule, rather than doing so when it is actually worn out or working inefficiently. The question is, could this strategy be costing more money if this action is taken prematurely? Conversely, condition-based monitoring uses sensors to monitor and assess the performance, quality, efficiency and status of machinery. The data collected can establish trends, predict failure, assess degradation and calculate remaining life. As a result, maintenance is only carried out when a consistent decrease in performance is identified, creating value through asset optimisation. Traditionally the only drawback with condition-based monitoring has been the high cost of implementation due to the use of proprietary infrastructure or integration into an IT network infrastructure. This is why up to 95 per cent of all machines inside process- based environments are only sporadically monitored, or not at all.
MONITOR AND MANAGE Although it makes sense to prioritise critical machinery, a chain is only as strong as its weakest link. So one piece of equipment failing can have a knock-on effect. Therefore, monitoring as much equipment as possible makes sense and enables the bigger picture to be seen.
The cloud and smartphone technology
have opened a new world of possibilities for developing next generation condition-
8 September 2021 Irish Manufacturing
based monitoring solutions, that are easy to implement and affordable, with quick returns on investment. Schaeffler’s OPTIME is leading the way in
this area, making it possible to detect potential damage, vibration, imbalances, knocking and/ or misalignments before they cause serious problems. In its simplest term you can Plug > Play > Predict
THREE OF A KIND OPTIME comprises three key elements. Firstly, wireless, battery powered vibration and temperature sensors are attached to machines to monitor their condition. Secondly, a SIM card enabled gateway receives data from the sensors via a Wirepas mesh network and transmits it straight into the cloud. This means that the system does not have to be integrated into a building’s IT network infrastructure, saving time and implementation costs. Finally, customers sign-up to a subscription- based service that uses advanced analytics, machine learning and proprietary algorithms to analyse data. This is turned into intuitive diagnostic reports that can be accessed via an app by designated Schaeffler Technical Engineers. It identifies anomalies, displays trends and, using a multi-stage warning system, provides a visual representation of the severity of a potential incident and the root cause of any problem. OPTIME can be installed and initial operation carried out without any prior CM expertise, and several hundred measurement points can easily be set up in a single day.
WALK IT LIKE YOU TALK IT Schaeffler doesn’t just advocate the use of OPTIME for others, it is used within its own production plant in Schweinfurt, Germany and is being rolled out at other plants within the group. Around 130 sensors, have been installed and machines are now monitored directly via the mobile app, resulting in cost savings in the five-figure range.
This experience is shared by Finnsementti, which produces cement, concrete, lime and other raw materials. Previously it had around 90 machine failures each year. The
company now uses OPTIME to monitor rotating machinery on a largely automated and permanent basis. Monitored machines can be organised into groups, enabling a scheduled maintenance programme to be created, which factors in personnel requirements and the procurement of replacement parts. Work can then be carried out without impeding production. OPTIME’s ability to prevent issues was one of the main reasons that a leading global provider of renewable solutions in packaging, biomaterials, wooden constructions and paper decided to install it. Having previously decided that the cost of implementing a CM solution was prohibitive, the low capital expenditure associated with OPTIME changed the company’s view. This proved to be a wise decision, as it indicated problems within 16 machines during the first few months of implementation. Likewise, shortly after a paper processing company installed OPTIME at its plant, the sensor on a vacuum pump motor issued an alarm concerning vibration intensity. Despite the sensor still operating in its learning phase, the company’s maintenance team confirmed that the motor had suffered bearing damage.
COST CUTTER Using sensors to measure the status of equipment while in operation provides actionable and meaningful insight.
Schaeffler
www.schaeffler.co.uk/OPTIME info.uk@
schaeffler.com
www.irish-manufacturing.com
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44
