A customer was eexperiencing mechanical failures on quench drives due to wear in the Teflon bushes supporting the quench rollers. This caused the rollers to drop and damage the sprockets and chains, causing the manufactured steel shoe to stick. The result was poor heat treatment of the shoes and subsequent quality issues. NSK recommended replacing the Teflon bushes with stainless steel Molded-Oil bearings. The bearings began a 12 months trial without problem and subsequently all bushes were converted in the quench area to NSK Molded-Oil.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|Cost of replacement parts - Chain, Teflon bushes, Sprockets, Rollers||$22,097||Cost of Molded-Oil bearings||$16,151|
|55 hours downtime @ $4,404 / hour||$242,220||No downtime||$0|
|Labor for maintenance 380 hrs @ $29 / hour||$11,020||No maintenance||$0|