Reliability improvement of rotating equipment’s by use of IIOT
Reliability improvement of rotating equipment’s by use of IIOT
At a glance
Focus: Reliability improvement of rotating equipment’s by use of IIOT.
Challenge: Spindle Failure breakdowns on Grinding Machine affects Productivity and Quality
Approach: Key steps were involved in going from ideation to decision
Impact: Zero surprise failure of 5 spindles
SKF India Ltd
SKF India is part of AB SKF, a leading global supplier of bearings, seals, mechatronics, lubrication systems, and services which include technical support, maintenance and reliability services, engineering consulting and training. SKF is represented in 130 countries with 108 manufacturing units. SKF India has 6 Manufacturing plants in India manufacturing Ball Bearings, Taper roller Bearings, Cylindrical roller Bearings, Spherical Roller Bearings and seals and lubrication systems
Business challenge
Spindle Failure breakdowns on Grinding Machine affects Productivity & Quality badly. Affecting customers in various Automotive, Industrial, Railway, aerospace and variety of customers
Repetitive quality failures of a key machine in one of the production lines
Vibration issues effecting quality due to spindle failure
Loss of production and production hours, adversely impacting customer delivery time & Quality
The following factors led to the discovery of the problem –
Repetitive quality issue
Increased down time
Unplanned shutdown
Production losses
Industry 4.0 solution
The following key steps were involved in going from ideation to decision making –
Changing the Machine panels:- clearer images are put up as below
Solving Methods to Real time IIOT based Techniques
MACHINE with IIOT Sensor
Data Transfer to HMI
Big Data from Transfer for Analysis to SKF Product
Installation of Online Vibration Sensors through SKF RDC IMx-8 technology
Real time action and decision using following
Micro-log and Vibration pens
System integration of “CoMo Projects”
Motor Current Signature Analysis (Baker)
Online systems and Portables
Remote Diagnostics Service
The solution could perform the following functionalities -
Real Time Action & Decision
Real Time Alert Communication through Smart spindle integration with old operations
Zero Surprise Failure - Smart Spindle
Technical enhancement for setting changes
Safety of operations
Predictive Maintenance supported by data validations
SMS
E-Mail
Key benefits
| Area | Outcome |
|---|---|
| Downtime & Reliability | Zero surprise failure of 5 spindles |
| Visibility & Analytics | Improved visibility for production planning |
| Energy & Sustainability | Sustainable quality parameters achieved |
| Visibility & Analytics | Real time data visibility |
| Downtime & Reliability | Removal of catastrophic failures |
| Safety & Workforce | Increased Safety |
| Downtime & Reliability | Reduced Downtime |
| Cost Savings | Reduction in cost of repairs |
| Quality | Scrap cost reduced by 15% |
| Productivity & Throughput | Efficiency improved from 70.1% to 72.3% |
Technologies used
Change management and implementation
The challenges were overcome through -
Old machine – System upgradation of machine display & identification for spindle sensor placement
Operator acceptance
Cost of new smart spindle
Creation of a focused cross functional team in agreement with the objective.
Experts from different areas consulted on technical parameters such as (Spindle load, sensor capacity and safety)
Cross validation with external consultants