The customer was experiencing regular bearing failure on a concrete floor manufacturing machine. This caused extensive downtime with associated lost production with high maintenance costs. This was of serious concern for management and an urgent solution was needed. NSK investigated the machine and found that the main problem was due to the cassettes poor wheel design, incorrect bearing selection and ingress of contamination. NSK produced a complete redesigned wheel hub and stub axle assembly including a sealed roller bearing assembly which was specifically selected for the loads in the machine. With this solution, failure rates reduced from 20 a year to zero.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|Lost production: 20 hrs / year @ $3,303||$66,043||No lost production costs||$0|
|Parts cost, old bearings + 16 hub & stub axle units||$6,140||Parts cost, new bearings||$317|
|Maintenance costs: ($44/h @ 20 hrs)
+ technical support & engineering time
|$1,982||Maintenance costs: ($44/hr @ 8 man hrs)
Technical support & engineering time no longer required