Success Story
Industry: Automotive Production
Application: Machine Centre
Cost Savings: $284,365
Introduction
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.
Key Facts
- Machine center with very arduous working conditions
- Failure of Ball Screws due to high loading and agressive environment
- NSK Solution: High-performance seals and high-speed/high-load Ball Screws
- Nut design Ball Screws to maintain better stiffness and improved quality
- Increased lifetime by 6 times
- Reduction in production downtime and material costs
- Machining Centre
- Ball Screw with High-performance X1 Seal Design
Value Proposals
- Plant survey including inspection of the machines environment and working conditions
- NSK analyzed three Ball Screws to observe the running paths and lubrication conditions
- NSK Technical Department designed a special Ball Screw that could be assembled without any change from the customer
Product Features
- High-performance seal design to work in a harsh environments
- Decrease in the operating temperature and wear (precision and preload)
- Increase of operating life, due to the greater load capacity and the lower preload
- Reduction of the torque required, due to a lower degree of preload, with a corresponding reduction of the energy consumption of the machine
- Reduced maintenance with K1 lubrication system
- Longer grease life
- Optimum lubrication even with high loads and harsh operating conditions
- No contamination of cutting/cooling liquid with grease
Cost Saving Breakdown
| 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 | |
| Total Costs | $289,068 | $4,703 | ||
Reference:SS-E-7028
