Eye on Failure is a series of articles about the stories of maintenance workers who have benefited from our platform, and eliminated failures and unplanned machine downtime. To know other cases, such as Embraer and AmstedMaxion, visit our blog.
Ahlstrom Munksjö is a company with global operations, accumulating customers worldwide. In Brazil, its headquarters are distributed in three plants, each one in a different city, all in the state of São Paulo. Ahlstrom is a global leader in fiber-based materials.
Pedro Henrique Nogueira started his career at the company in 2018. As a trainee, he assisted in the electrical sector and two years later he was hired as a metrology assistant. Pedro never let his lack of experience in the field delay his growth. He has always studied and sought to be constantly updated since the area demands it.
Since I joined Ahlstrom I got to learn more about other fields of maintenance and participated in some projects, such as the implementation of the SAP PM module.
Pedro explains that the plant has been established in the city for over a hundred years. Therefore, introducing Industry 4.0 was very complicated due to the culture already established up to that point. In addition, most assets require constant maintenance, as they operate every day of the week.
Before TRACTIAN, machine health was supervised by an outsourced maintenance company that did a predictive analysis once a month, sampling data at each vibration spot. A while later, they would have in their hands a report and history on the state of the assets.
Pedro says that it was complicated to perform accurate maintenance because the sampling of information was done monthly. The delay to receive a correct diagnosis on the equipment was also a major problem.
The thought of improving maintenance processes occurred when the equipment started presenting problems and downtime was a constant reality.
That’s where TRACTIAN comes in. Initially, the company acquired 10 sensors to learn more about the solution. After only two months, the benefits and gains obtained motivated the maintenance team to upgrade to 33 sensors.
The ease of access and reliability provided by the platform made Ahlstrom expand to 77 sensors after only two months. By having more monitored equipment, the assertiveness in data and repair routines increased. That verifies the company’s satisfaction, demonstrating how relevant it is to the daily routine of the professionals there.
When we started to monitor machines remotely, there was no need to be on-site anymore.
Thanks to the innovative way of performing maintenance, it was possible to identify two motors that presented bearing failures and wrong fastening. And before an emergency stop could happen, the bearings were replaced and the solution prevented two machines from breaking down.
A rupture of 38.87% more than acceptable was noticed, where the limit was 8.9649 and the rate reached was 12.4500. Therefore, the sensor issued an alert, an insight of a change in the vibration profile was sent by our platform, and the maintenance team acted before a more serious problem occurred.
The sensors make the life of maintenance professionals easier. By making a more precise analysis of what is happening with the equipment and why they are presenting problems, you can evaluate the asset and the place where it’s located.
Ahlstrom has acquired 30 more sensors, meanwhile, Pedro and his team are looking forward to expanding their condition monitoring system.
We have real-time monitoring. This is awesome because I can be at home and know if the machine is running or if there’s been a problem. I can monitor them and see if the equipment is malfunctioning, and it doesn’t matter what day it is or where I am.
The maintenance sector, which previously generated high costs, had an upgrade after the sensors were set up. The platform pointed out an engine that was showing a problem in its bearing – that could lock it and even burn the entire equipment. Thanks to the sensor, it was possible to anticipate the failure. This way, the company only paid for a replacement bearing and not a brand new motor.
According to Pedro, a sensor that collects so much information and has several functionalities at an affordable price is simply fantastic. The communication between team and platform is another point that draws a lot of attention.
“You don’t need to have a network integrated into the sensor. It does this with a smartphone chip signal, and it made our life here much easier. We don’t have to involve other areas to pull a cable and make the connectivity work, because everything is done automatically. How easy the sensors are to set up is also something to highlight.”
If you want equipment effectiveness and more reliability for your machines, follow Pedro’s footsteps: talk to our experts to start using TRACTIAN and leave conventional maintenance behind.
About the author:
Santa Catarina State University graduated engineer, with more than 10 years of experience in Industry 4.0, metalworking, machine manufacturing and hydraulics. Head of Customer Success at TRACTIAN.
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