Success Story

Industry: Power Transmission

Application: Bus Gearbox

Cost Savings: 37,667 euros

Introduction

An international manufacturer of angle gears was experiencing frequent and irregular failures on gearboxes fitted to a bus application. NSK investigated this and found the bearing arrangement was complex involving many components from alternative suppliers. As a result, NSK proposed a customised solution with an integrated flanged bearing arrangement which simplified the assembly and gave superior performance. A trial proved this to be successful. The solution was adopted by the customer, resulting in reduced parts needed, consistent performance and guaranteed assembly. This gave the customer a significant cost saving with reduced maintenance costs and improved product performance.

Key Facts

Bus gearbox
Irregular and unscheduled failures
Failures through complex and often incorrect assembly of bearings and components
Demand for increased service life
Trials with NSK flanged bearing units
Approval of NSK product and adaption into production
Result: reduction of assembly costs and labour costs

Bus drive gear

NSK Flanged Bearings for gearboxes

SS-E-1004

NSK Europe - http://www.nskeurope.com

Background Information

Sector: Power Transmission
Country: Germany
End product: Bus
Application: Drive gear

Number of gearboxes: 4,000
Approx. lifetime: 27 weeks
Problem: failures through complex and often incorrect assembly

Value Proposals

NSK’s investigation showed that problems arose during installation of the bearings
NSK training of employees in the installation and removal of bearings
Special NSK design solution using flanged bearing units

Reduction of assembly costs and labour costs
Great improvement in the bearing performance and reliability
Cost savings of approx. €37,667 per annum

Product Features

35° contact angle for high axial forces
Compact design
Special shaft seal with vent hole

Negative operating clearance
Housing coated against rust
Housing sealed by O-ring

Cost Saving Breakdown

Before		Cost p.a.	NSK Solution	Cost p.a.
	Bearing costs (incl. parts)	€112.000	Costs of NSK flanged bearings	€146.000
	Assembly costs (4.000 x 466h)	€16.333	Assembly costs (4.000 x 133h)	€4.666
	Labour costs for replacing bearings	€60.000	Labour costs for replacing bearings	€0
Total Costs		€188.333		€150.666

Reference: SS-E-1004