A customer was experiencing repeated failures on bearings fitted to roller assemblies on his wire drawing machinery. This resulted in excessive downtime and high maintenance costs. This was a serious concern to the management and a solution was needed urgently. NSK was called in to investigate and found that there was a lubrication and sealing problem. A new bearing and lubrication package was tested. Results showed that this solution significantly improved the bearing performance resulting in large improvements in productivity and a reduced maintenance cost.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|Constant failure of bearings / 75 Rolls changed per month||Significant improved reliability / 45 Rolls changed per month|
|0.5 hours per change / €6.000 per hour lost production cost / €225.000 per month x 12 months
||€ 2.700.000||0.5 hours per change / €6.000 per hour lost production cost / €135.000 per month x 12 months||€ 1.620.000|
|378 man hours / €13.986 cost per month / €13.986 x 12 months||€ 167.832||108 man hours / €3.996 cost per month / €3.996 x 12 months||€ 47.952|
|Technical Support & Engineering Time||€ 2.575||No Technical Support needed||€ 0|
|Total Costs||€ 2 870 407||€ 1 667 952|