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 |
Reference:SS-E-2018