Customer Success Story
with OPTIME from Schaeffler
Schaeffler OPTIME prevented unplanned downtime in the supply systems at the Schaeffler plant in Schweinfurt, resulting in cost savings in the five-figure range.
Benefits
Easy and rapid installation of OPTIME components.
Easy data reading: no expert knowledge required.
Greater security for employees, as access to hard-to-reach machinery is no longer required with the digital service.
Cost-effective solution for comprehensive and wireless monitoring of units.
Permits long-term planning of maintenance measures, personnel requirements, and in the management of replacement parts.
Unplanned downtime is no longer an issue for monitored machines.
Challenge
At the Schaeffler plant in Schweinfurt, rotating machines are used in a hardening shop around the clock, in addition to various supply systems. The Maintenance Manager, Detlev Jacobi, was looking for a reliable and cost-effective addition to the existing condition monitoring system, as downtimes in production systems caused by the failure of auxiliary units, such as motors, pumps, or fans for example, are always associated with high costs. Consequently, the primary aim of a new monitoring solution was to vastly reduce maintenance costs.
In addition, the solution was intended to provide better protection for personnel, as auxiliary units are generally difficult to access and therefore pose a safety risk. For this reason, the Maintenance Manager sought assistance from the Industry 4.0 experts within his own company.
Solution
Customers receive clear statements about the condition of their machines via a mobile app. The installation of 130 sensors was completed in just a few hours. Consequently, hundreds of machines at the Schweinfurt plant are now monitored directly via the mobile app, and with great success. After just six months, an outer ring defect on the exhaust air motor and the threat of damage to the supply air motor were detected in a supply system (see status message opposite).
Status | Trend | Machine | Diagnose | Actions | First Finding | Based on |
| ➔ | Build. 26/2 Supply air motor | Advanced outer race defect of the bearing NU 313 ECP | Advanced outer race defect of the bearing NU 313 ECP | 24.02.2020 | Raw data |
| ➔ | Build. 26/0 Exhaust air motor | High vibration amplitudes | Check the sensor mounting and the machine condition | 24.02.2020 | Raw data |
Machine status always identifiable at a glance via smartphone, tablet, or PC.
What’s Special
Schaeffler OPTIME is soon to be installed throughout the plant. The solution can be applied across sectors. OPTIME has been available on the European market since July 1, 2020.
Technical Details
Technical information on the hardening
6 lines, 130 t/day, 3 lines monitored with OPTIME
31 OPTIME sensors on circulating air fans
950–1500 rpm
Fixed and regulated speed
200 °C
2,2–10 kW
Technical information on the supply systems
50 ventilation and media supply systems
8 systems monitored with OPTIME
Approx. 100 OPTIME sensors on motors, pumps,
ventilators, plummer block housing units, and belt drives
1500 rpm
Fixed and regulated speed
8–20 kW
Savings
In total, there are 6 hardening facilities in Schweinfurt. Assuming a failure rate of 30%, this gives a potential annual saving of € *117,000
In total, there are 50 supply systems in Schweinfurt. Assuming a failure rate of 30%, this gives a potential annual saving of € *222,000
*The one-off acquisition costs and the annual costs for the digital service are to be deducted from this figure.
