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Home | Smart Performance Program: Increased efficiency through condition-based maintenance
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Smart Performance Program:
Optimised maintenance processes at an automotive supplier
Herzogenrath, November 9, 2009. Through regular condition measurements on extruder motors, the automotive supplier Kautex Textron is saving 12,500 Euro annually on maintenance costs. In order to increase its knowledge of machinery condition, the company uses the mobile vibration measuring device FAG Detector III. This not only allows rapid and reliable monitoring but also contributes, through the functionality of automatic measurement point detection, to the optimisation of maintenance processes.
Efficient and highly qualified maintenance is the decisive factor for secure and economical plant operation. This aspect is particularly important for production-critical assemblies, which in the field of plastics processing includes the extruders. Their motors are subjected to continuously high loads because, while the material is being pressed out out of the extruder screw, it exerts large forces on the upstream machine unit. At the same time, failures cause not only costly downtime but can also lead to production bottlenecks. In order to avoid this, the Kautex Textron plant in Leer (Germany) decided to introduce the mobile, portable vibration measuring device FAG Detector III. After a two-day instruction course by FAG Industrial Services (F’IS), the employees of Kautex Textron have recently started carrying out regular measurements on the extruder motors themselves. Optimum machine production is ensured by means of configuration templates prepared specially for the extruders by F’IS. As a result, incipient damage is detected at an early stage by the measuring system. Where necessary, there is also the option to forward any data sets with conspicuous characteristics to the vibration experts at F’IS for more detailed analysis. The function for automatic measurement point detection ensures that all the assemblies defined in a measurement round are identified precisely and without errors by the FAG Detector III – irrespective of the sequence in which they are selected during an individual measurement procedure. The assemblies are fitted with RFID tags, which improves the process operations and process quality in maintenance.
The objective of Kautex Textron is to achieve a significant reduction in machine breakdown and costs. The number of annual breakdowns is to be reduced from six to one, which would minimise the costs from 6,000 to 1,000 Euro. A further objective is to extend the machine running time. The intention is to stretch the overhaul interval from the current 12 months to 18 months, which would give a further 7,500 Euro in savings per year. The maintenance costs would thus decrease by 12,500 Euro per year. Furthermore, the company benefits from improved plant availability, compliance with delivery targets, reduction in production downtime and lower consumption of resources.
Kautex Textron GmbH & Co. KG is one of the world's leading plastics processing companies. At the Leer location, production is carried out exclusively for the automotive industry in a plant built specifically for manufacture of the fuel tank for the VW Passat. The largest customers include Volkswagen and Opel as well as other Kautex plants both domestic and foreign.
FAG Industrial Services GmbH (F'IS) Headquartered in Herzogenrath near Aachen, FAG Industrial Services GmbH (F'IS) offers its services, service products and maintenance training on a manufacturer-independent basis, helping customers to save on maintenance costs, optimize machine availability and avoid unexpected machine downtime. F'IS takes responsibility for Schaeffler Group Industrial's worldwide service business regarding the INA and FAG brands. In 2008, the Schaeffler Group employed a workforce of about 66,000 at 180 locations worldwide and generated sales of EUR 8.9 billion with its brands INA, LuK and FAG.
Contact FAG Industrial Services GmbH Sabine Drescher Marketing & Communication Tel. +49 (0)2407 9149-78 Fax +49 (0)2407 9149-59 E-mail: drescher_s@fis-services.de
Press Contact If you need any further information, don't hesitate to contact us. |
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