Worthington Delta
Furnace roll bearing save prevents $500k loss and averts 48 hours of downtime.
From Challenge to Solution
Every project comes with obstacles. Here’s how we identified the problem and built a solution that delivered lasting impact.
The Challenge
Unplanned downtime destroys profitability in continuous process manufacturing. In their quest for operational excellence, Worthington Steel searched for a remote condition monitoring solution to reduce machine failures and increase uptime at their Toledo hot-dipped galvanizing facility. The steel processor implemented Vero® across the plant and realized an 18% decrease of machine-related downtime and a 17% reduction in reworks.
The Solution
The Worthington Steel Delta Galvanizing Plant, located near Toledo, is a clear example of how machine health insights can drive proactive maintenance and deliver stellar returns.
Within weeks of installing Vero®, the early detection of a furnace roll bearing failure by the AssetWatch® Condition Monitoring Engineer (CME) allowed for the planning of its replacement on a down-day. The bearing vibration was undetectable by naked ear and touch.
If this bearing had failed during a line run, it would have caused approximately 48 hours of unplanned downtime and potentially $500k in lost gross margin.
Below are the results from the first six months of Vero® service at the facility.
Quantifying Success
The numbers reveal the true impact of our solution. From efficiency gains to cost savings, these results demonstrate the measurable value we delivered.
Facility Savings
Potential lost gross margin saved in just the first six months of Vero service
Increase in Overall Plant Efficiency
Vero helps optimize production, increasing OEE
Reduction in Reworks
Reducing unnecessary and costly reworks immediately increases profitability
Decrease in Machine-Related Downtime
Early machine health insights allow for proactive maintenance and reduced downtime
Downtime Risks Resolved
Condition Monitoring Engineers work with customers until issues are resolved
Maintenance Recommendations
Prescriptive maintenance recommendations issued by expert Condition Monitoring Engineers
With our AssetWatch® Condition Monitoring Engineer, I feel like I have a highly qualified tech on my team.
Condition based monitoring in action
Within weeks of installation, the Delta Plant we had a HUGE win with early failure detection and proactive, planned replacement of a furnace roll bearing, preventing approximately 48 hours of unplanned downtime and potentially $500k in lost gross margin.
Return On Investment
One Sensor Saved a Potential $500k in Lost Gross Margin!
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Powering Predictive Insights with AWS
AssetWatch partnered with AWS to provide the scalability and reliability needed to support a serverless architecture. With a robust suite of services tailored for data ingestion, processing, and machine learning, AWS enables AssetWatch to seamlessly scale sensor data and deliver predictive insights to manufacturing companies.
AWS infrastructure reduces operational overhead and allows AssetWatch to focus on innovation to drive value to our customers. Additionally, AWS’s strong security framework and global infrastructure ensure the resilience and compliance required to support mission-critical manufacturing operations at scale. This partnership positions AssetWatch to accelerate growth while maintaining the highest levels of performance and reliability.
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One Sensor Saved a Potential $500k in Lost Gross Margin!
Worthington Steel Cuts Downtime with Vibration & Oil Analysis
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