A customer was experiencing repeated bearing failures fitted to roller assemblies on their wire drawing machinery. The failures were resulting in excessive downtime and high maintenance costs. Management was concerned about the increasing cost. A solution was urgently necessary. NSK was called in to investigate and found that there was sealing and lubrication problem. A new bearing and lubrication package was tested and the results showed significant improved the bearing performance. Productivity increased and maintenance cost were reduced.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|Constant failure of bearings / 75 Rolls changed per month||Significant improved reliability / 45 Rolls changed per month|
|0.5 hours per change / $6,428 per hour lost production cost / $241,042 per month x 12 months||$2,892,504||0.5 hours per change / $6,428 per hour lost production cost / $144,585 per month x 12 months||$1,735,020|
|378 man hours / $14,983 cost per month / x 12 months||$179,796||108 man hours / $4279 cost per month / x 12 months||$51,348|
|Technical Support & Engineering Time||$2,758||No Technical Support needed||$0|