A worldwide manufacturer of automotive components was having significant unplanned stoppages due to the failure of the Ball Screws in the Machining Center. This had a major effect on the manufacturing output resulting increased costs and reduced machine reliability. The average life of the Ball Screws was about 6 months. NSK analysed three of the failed Ball Screws to determinate the main reason of the failure. NSK's Technical Department developed a special design to improve all the technical characteristics, especially the high-performance sealing design. Two Ball Screws were installed in the most critical points in the plant. This was successful and led to a cost saving and reduced machine downtime and a massive increase in lifetime.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|Costs for Ball Screws x 2 machines||€ 8.400||Costs for Ball Screws x 2 machines||€ 4.000|
|Production costs: 6 hours/stop x 12 stops x 360 pieces/hour x 10€/piece||€ 259.200||No failures in 36 months||€ 0|
|4 hours for each Ball Screw x 50€/hour x 14 changes||€ 2.800||4 hours for each Ball Screw x 50€/hour x 2 changes||€ 400|
|Total Costs||€ 270.400||€ 4.400|