AssetWatch's Condition Monitoring Engineers (CME) reduce the work load and increase efficiencies for maintenance and reliability teams by monitoring machine health data and alerting customers to potential faults before they occur, allowing for scheduled proactive maintenance, not reactive repairs.

In the case of this plastic film manufacturer, the CME alerted the customer to an extruder gearbox issue developing on one of their most profitable lines, leading to the discovery of 0.0005” radial play on the input shaft of the gearbox, versus the tolerance of only 0.0003”.

After pulling the shaft and replacing bearings on the 1960s-era gearbox, inspection of the lower end gears found minimal wear and the early detection allowed for preservation of the gear set.  

Customer was alerted in time to run their remaining raw materials, take down the line naturally, install new bearings, and complete preventive maintenance on the line with no production loss, avoiding an estimated 1,200 hours of downtime for a gearbox rebuild.

The customer estimated they saved $1.2M with Vero^® in just 12 months and subsequently expanded the proactive maintenance solution into two additional manufacturing facilities.