A worldwide manufacturer of automotive components was experiencing significant unplanned downtime due to the failure of the Ball Screws in the Machining Center. This had a major effect on the manufacturing output resulting in increased costs and reduced machine reliability. 6 month was the average life of the Ball Screws. NSK analyzed three of the failed Ball Screws to determinate the main reason for the failures. NSK's Technical Department developed a special design to improve the technical characteristics, especially the high-performance sealing design. Two Ball Screws were installed in the most critical points in the plant. The product testing was successful. Reduced machine downtime and a major increase in ball screw life were achieved.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|Costs for Ball Screws x 2 machines||$8,980||Costs for Ball Screws x 2 machines||$4,276|
|Production costs: 6 hours/stop x 12 stops x 360 pieces/hour x $10.85/piece||$277,095||No failures in 36 months||$0|
|4 hours for each Ball Screw x $54.28/hour x 14 changes||$2,993||4 hours for each Ball Screw x $54.28/hour x 2 changes||$427|