A market leading manufacturer of insulation products for the construction industry had recently completed commissioning of a new automated production line. Production was however reported as being erratic due to repeated failures of bearings used on the blade guide rollers of the band saws. The situation had become critical with daily bearing changes becoming necessary; in some cases bearings were only lasting 3 hours. The impact was costly downtime and increased maintenance. NSK was contacted on behalf of the band saw manufacturer to help identify route cause for the failures and offer solutions.
Before | Cost p.a. | NSK Solution | Cost p.a. | |
---|---|---|---|---|
1/3 of bearings changed daily | € 16.930 | Complete bearing sets Changed 4 times per year During planned maintenance |
€ 1.060 | |
Replace bearings at band saws Part bearing sets only 3 band saws 4 times per week |
€ 24.320 | Installation of bearings on 3 band saws | € 380 | |
15 minutes per bearing 3 band saws (part bearing sets) 4 times per week |
€ 607.800 | No unplanned downtime | € 0 | |
Damaged saw blades | € 1.270 | No bearing failure causing saw blade damage | € 0 | |
Total Costs | € 650 320 | € 1 440 |
Reference:SS-E-2059