Water

Company

Created in 1981, this company provides water and wastewater services to millions of residents of one of Europe’s largest and fastest-growing cities. It is under pressure to provide water to ever-higher standards and to become more cost-efficient, while coping with increasing demand. Its large network of pumping stations and treatment works are spread across a wide area.

Challenges

The company has embarked on a number of initiatives to drive down costs and improve performance, including the critical need to move away from a breakdown maintenance strategy to condition monitoring. As part of this program, maintenance staff were challenged to reduce equipment downtime significantly while alsoreducing their annual maintenance spend. Critical assets are located in very different environments, some in remote and inaccessible areas, and many others right in the heart of densely-populated areas that can only be accessed through traffic-choked streets.

Solution

Senior specialists for the network carried out a detailed analysis of condition monitoring technologies that would allow them to improve performance of their key assets. Critical factors in their selection of Artesis MCM were:

  • Ability to provide monitoring and diagnostics for both pumps and the motors driving them
  • Ease of retrofitting to installed pumps
  • Clear and early warning of developing faults
  • Combination of local displays for onsite staff with remote, central monitoring

Results

Within a month of the installation of the Artesis MCM system, it accurately diagnosed a fault on a critical non-return valve, allowing for timely correction and avoiding a breakdown. This increased confidence in the capabilities of the system, which local and central staff increasingly relied on for predictive assessments.

In the first year of operations, the division was able to reduce maintenance costs by 10%through avoidance of breakdowns and reductions in spare parts. MCM is now being retrofitted across the organisation, and is also part of the standard design specification for new installations.

Automotive Parts

Company

This company is a manufacturer of automotive parts to Toyota, Honda, and Daimler Chrysler. Such customers demand that its complex sound insulation products combine exceptionally high quality with competitive costs. Lean manufacturing methods have been effectively combined with advanced technology to build on their position as a major global partner.

Challenges

Productivity at this company is critically reliant on the reliability of its manufacturing machinery. Although the maintenance team had implemented a rigorous planned maintenance program on critical pumps, presses, compressors and waterjet cutters, the failure rate continued at an unacceptable level that required emergency repairs on a daily basis. As well as impacting availability, this also meant that the maintenance technicians were forced to focus on constant breakdowns rather than process improvements.

Solution

The maintenance team had a good understanding of the potential benefits of condition monitoring. As well as allowing them to reduce downtime costs, this could also free them from the need for frequent emergency repairs so that they could focus on major reliability improvements. They selected Artesis MCM after an extensive review process because it provided the results they needed without the complexity and cost of more traditional approaches. It was also able to provide diagnostic information directly to their maintenance management system for immediate action.

Results

After less than a year of use, Artesis MCM has helped this company to cut unplanned downtime to less than 1%-a performance that has been instrumental in meeting the requirements of the ISO TS 16949 quality certificate, as well as an A class supplier rating from Daimler Chrysler. The initial Artesis MCM installation paid for itself comfortably within the first year, leading to a further installation at a second plant. Many other parts of the group have recognised the accomplishment of the condition monitoring team and are in the process of establishing similar programs.

Automotive

Company

Producing more than 40% of the automobiles in its home market and with a rapidly-growing export market, now exceeding $2B annually, this manufacturer has achieved a global reputation for reliability and cost-effectiveness. It is now engaged in releasing a new generation of automobiles to all its major markets.

Challenges

Increasing focus on productivity forced this company to address a history of conveyor system failures on three major production lines that had impacted operations for several years. Bearing and insulation failures on drive motors had beenfailing unexpectedly despite the adoption of a planned maintenance program, leading to a cumulative loss of several days of production every year and pushing the plant’s Overall Equipment Effectiveness down by a full %. Increasing exports eliminated any spare manufacturing capacity, and finding a solution became a critical issue.

Solution

Although it quickly became clear that condition monitoring of the conveyor systems had the capability to predict failures weeks in advance and avoid the run of failures, finding the right system was a key factor. The company selected Artesis MCM after a careful review of many systems, not only because it was possible to install at the motor control cabinets (avoiding the need for significant new cabling) but also because it excelled at early detection of bearing and insulation problems (their two major faults). As few as 20 MCM units were required to cover all critical equipment.

Results

Typical failure events resulted in around 40 production staff remaining idle for up to 4 hours while repairs were carried out. Increasing export success meant that this loss could no longer be corrected by overtime working, and the cost of lost production exacerbated the cost of lost man hours.

The use of Artesis MCM completely eliminated these failure events, the cost of each of which has been estimated at $100-200Kand which had been occurring several times a year, for less than $100K. This high return on investment has led to the progressive deployment of Artesis MCM in several other plants.

White Goods

Company

Since it’s foundation in the 1950s, this company has grown to be one of the world’s largest manufacturers of white goods. It has 250 million customers, and continues to sell a product every 2 seconds in over 100 countries. Its washing machine plant makes extensive use of highly- automated production lines to produce more than 1 million machines a year.

Challenges

Volume manufacturing of white goods is critically dependent on the efficient scheduling of each of the stages of manufacture. And as its customers haveraised their expectations for finish quality, the paintshop has gradually become a bottleneck as a result of more frequent rework to correct imperfections. Since most of those problems have been caused by failures of motor-driven conveyors and fans, this manufacturer embarked on a program to increase productivity by avoiding thosefailures altogether.

Solution

Several members of the maintenance team had previous experience of the advantages of condition-based maintenance, but recognised that conventional approaches would not be effective in a busy manufacturing plant. In particular, they did not have access to the analysis effort that such systems typically require.

After a long series of discussions with Artesis, they became convinced that the automated diagnostic capabilities of MCM would meet their needs well. An initial installation of 26 units on their most critical conveyor and fan systems was later expanded to over 100 as confidence in the approach increased.

Results

The condition monitoring program has been an outstanding success, with the productivity of the paintshop increasing by 50% as the need for rework reduced. Equipment failures have been driven down to 1% of their previous level, and product faults to 10%. Maintenance staff particularly recognise the importance of the 25% reduction of customer complaints resulting from this initiative.

The important role of Artesis MCM in the success of this program is well-recognised, and is leading to the wider deployment of the system through the organisation.