Worthington Proactive
Achieving a proactive maintenance culture and increasing plant reliability.
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
In 2017, Worthington Steel embarked on a maintenance challenge. Their goal was to improve overall plant reliability, and transform their maintenance and reliability division from a reactive culture to a proactive one. It was a visionary look toward the future for the global metals manufacturing company.
The Solution
Following the blueprint of its five-stage Reliability Triangle, with the ultimate goal being to achieve operational excellence and to target 100% machine reliability, Worthington Steel first established and executed a planned maintenance strategy.
But to achieve the next stage, a truly proactive maintenance culture, the company needed an affordable and comprehensive condition-based predictive maintenance solution. That's when Worthington Steel partnered with AssetWatch®.
With the AssetWatch® team responsible for installing and maintaining the wireless condition monitoring system, analyzing machine health data, and providing prescriptive maintenance recommendations, Worthington Steel was empowered with the tools, data and insights needed to make better decisions and the time to proactively schedule maintenance before critical machines fail.
Since partnering with AssetWatch®, Worthington Steel has seen enormous gains from the cultural transformation to proactive maintenance as well as the ongoing financial benefits of saving millions of dollars annually across the 17 plants being monitored by AssetWatch®.
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.
Customer Savings
Potential lost gross margin saved with Vero
Wireless Sensors Collecting Data
Rugged sensors collect high-quality, full spectrum vibration and temperature data
Monitored Facilities
Rapid system deployment enables enterprise scalability
Downtime Risks Resolved
Early insights into machine health prevent unplanned downtime
Healthy Machine Assets
Vero® protects all stationary rotating equipment - motors, pumps, fans, bearings, gearboxes, etc.
Data Points Analyzed
Vibration and temperature readings analyzed by ML and expert Condition Monitoring Engineers
Once the planned maintenance strategy was operating, we saw improvements — but the next step, proactive maintenance, based on predictive maintenance and condition-based monitoring, would be where significant gains would be realized.
Condition based monitoring in action
Within weeks of installation, the Delta Plant had its first big win. We detected a potential failure and suggested a replacement of a furnace roll bearing which prevented approximately 48 hours of unplanned downtime and $500k in potential lost gross margin.
Return On Investment
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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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