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Eye on Failures: Emerson from Master Brakes

Maintenance cannot be left out of the technological evolution. The industry needs to look for tools to follow new trends in search for excellence, becoming more evidently an area that adds value to the business. For this it is necessary to constantly update the change Mindset related to the search for innovations and new technological trends.

– Emerson Duarte

He is an enthusiast of new technologies and innovation for the industrial maintenance area and has more than 20 years of experience in the area, having participated in several phases within Randon Companies.

A JOURNEY OF lots of LEARNING

Emerson has 20 years of experience in industrial maintenance, specifically at Randon Companies.  He currently works at Master Sistemas Automotivos as Maintenance Analyst, focusing on TPM, audits and innovation projects.  Throughout this period, he has accompanied and participated in many movements such as the expansion of the industrial park, acquisition of new equipment, restructuring of the maintenance sector and culture change.

Currently, besides working on TPM and audits, he is participating in the creation of the maintenance sector of Ferrari, a foundry belonging to Master, and is also working on innovation projects within the maintenance sector.

According to Emerson, we must always seek excellence in the activities performed by maintenance, both in routine activities and in new projects, in this case the partnership project with the Startup “Tractian”.

The expectation with this partnership is very high. We have already managed to act in a proactive way, avoiding breakdowns that would certainly impact the delivery of our products and billing. We always work focused on our clients, seeking effectiveness in our work and certainly Tractian is helping us a lot.

– Emerson Duarte

SAVING INSIGHTS

Emerson comments that the company has more than 250 pieces of equipment and it was difficult to monitor all components, especially the critical ones, as to also guarantee their availability.

In a conventional predictive maintenance, the measurements are carried out monthly, in this period a simple anomaly can worsen causing the breakdown of equipment and unexpected stops in the production process.

By monitoring the platform online, it is possible to carry out the management of these components with precision and assertiveness, since several checks are carried out during the day.

Among the cases in which our platform was crucial, we can highlight 2.

Dial Machine operation 30: This equipment makes the machining of the Caliper, an important item for Master’s exportation market. For information, Dial Machine has 3 stations, with 10 heads each, and today Tractian is monitoring operation 30, which is the bottleneck(main spend). Emerson says that they chose this section to monitor because “the operation is extremely critical, and it would cause a complete stop in the production flow of this equipment.”

During its period working, the sensor sends alerts, an insight of anomalous vibration was detected by the platform, saying that there needs to be action taken as soon as possible, and as maintenance staff verified there was a serious problem. “The problem occured in the spindle or coupling of the servo motor, which was due to fail, and we would lose practically an entire work shift. That is, there would have been 4 operators stopped (on duty?) and about 1000 parts that would not be produced”.

Through this notification, the maintenance team was able to anticipate and correct a problem that otherwise would become serious.

Mori Seiki “O”: This machine presented a specific “Insight” of a water pump. We directed the maintenance team to assess the problem. By replacing a suction filter, we prevented the pump from malfunctioning and stopping the machine. “Now, like real-time monitoring, it is possible to identify anomalies and act preventively and with greater assertiveness.”

In this case, our platform issued an insight due to the temperature limit reached by the equipment. When the problem was found, the filter was replaced and the pump housing was cleaned, which meant the equipment returned to normal operation.

PROMOTES SAFETY AND PRECISION

Before the implementation of the sensors, the Master team had recently replaced the main wheel bearing on a 1000T press machine, Emerson points out that this condition required continuous monitoring, due to the criticality of operation and the breakage history.

“There was a risk involved in the daily monitoring of the vibration and temperature of the steering wheel bearing, due to the height of the press and the difficulty of access by the technicians. Activities with work at heights require training and mandatory compliance with safety standards. The time wasted in this entire verification process was around 40 minutes per day.”

After commenting on this constant concern with the press machine, Emerson highlighted the change that occurred after the installation of TRACTIAN sensors and the access to online monitoring: “The sensors brought greater security, precision and reliability in monitoring. Currently it is possible to follow in real time through the platform and using the application installed on the cell phone, with the information “in the palm of your hands”

Emerson – “This work of innovation and change of Mindset, is only possible due to the support and unconditional support of our management, Coordination, Management and Directors, are the motivators and sponsors of this transformation of Master for an industry 4.0”.

I feel motivated and challenged in this project, as well as I am convinced that it will add a lot of value to our business in the future.

– Emerson Duarte

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Sobre o Autor:

Alex Vedan

Industrial Designer by UNESP (State University of São Paulo). He specializes in product design with an emphasis on digital manufacturing, innovation and communication. Contributing to the creation and relevant content for industry. Head of Marketing at TRACTIAN.

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