A market leading manufacturer of insulation products for the construction industry had recently completed commissioning of a new automated production line. However, production was reported as being erratic due to repeated failures of bearings used on the blade guide rollers of the band saws. The situation became critical with daily bearing changes becoming necessary; in some cases bearings were only lasting 3 hours. Costly downtime and increased maintenance became an issue. NSK was contacted on behalf of the band saw manufacturer to help identify route cause for bearing failures and determine a solution.
Before | Cost p.a. | NSK Solution | Cost p.a. | |
---|---|---|---|---|
1/3 of bearings changed daily | $18,134 | Complete bearing sets Changed 4 times per year During planned maintenance |
$1,135 | |
Replace bearings at band saws Part bearing sets only 3 band saws 4 times per week |
$26,048 | Installation of bearings on 3 band saws | $407 | |
15 minutes per bearing 3 band saws (part bearing sets) 4 times per week |
$650,998 | Downtime eliminated | $0 | |
Damaged saw blades | $1,360 | No bearing failure causing saw blade damage | $0 | |
Total Costs | $696,540 | $1,542 |
Reference:SS-E-2059