A customer was facing mechanical failures on quench drives due to wear in the Teflon bushes supporting the quench rollers. This led to the rollers dropping and damaging the sprockets and chains, causing the manufactured steel shoe to stick. The result was poor heat treatment of the shoes and subsequent quality issues. NSK recommended replacing the Teflon bushes with stainless steel Molded-Oil bearings. The bearings were on trial for 12 months without problem and subsequently all bushes were converted in the quench area.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|Cost of parts replaced - Chain, Teflon bushes, Sprockets, Rollers||€ 20.614||Cost of Molded-Oil bearings||€ 15.067|
|55 hours downtime @ € 4.109 / hour||€ 225.995||No downtime||€ 0|
|Labour for maintenance 380 hrs @ € 27 / hour||€ 10.260||No maintenance||€ 0|
|Total Costs||€ 256 869||€ 15 067|