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Eye on Failures: Tiago Junqueira from AmstedMaxion

Eye on Failures: this is a series of articles about the stories of maintainers who have benefited from our platform and have been spared from sudden crashes.

A JOURNEY OF MANY LEARNING

AmstedMaxion, Tiago Junqueira is a maintenance supervisor at the company that manufactures steel wheels, railway castings for bogies, shock systems and traction for industrial castings.

With a degree in industrial production management from Fatec, and a postgraduate degree in engineering and maintenance management, the supervisor had his entire career built within AmstedMaxion, from his apprenticeship at Senai in 2006, until his current position.

AmstedMaxion, located in Cruzeiro-SP, is considered the largest smelter in South America, using state-of-the-art technology to produce parts from 10 kg to 5 tons, in carbon and low-alloy steel. It produces a diversified line of railway castings and, in the industrial segment, manufactures parts that supply the mining, machinery and equipment for civil construction / off-road truck and sugar and alcohol sectors, operating in the domestic and foreign markets.

AmstedMaxion, located in Cruzeiro-SP, is considered the largest smelter in South America, using state-of-the-art technology to produce parts from 10 kg to 5 tons, in carbon and low-alloy steel. It produces a diversified line of railway castings and, in the industrial segment, manufactures parts that supply the mining, machinery and equipment for civil construction / off-road truck and sugar and alcohol sectors, operating in the domestic and foreign markets.

SAVINGs INSIGHT

Tiago says that the first contact with the Tractian was in November 2020, where there was knowledge of the sensors and the platform, and 12 were installed in January 2021. Before the use of the startup’s technology, unexpected crashes were recurrent at AmstedMaxion. The supervisor details that it was not possible to obtain information to understand, and to predict which equipment would fail and when. It also details that after the installation, it was possible to better understand the data of the assets and, consequently, avoid sudden breakdowns:

“We had a significant increase in the information about assets, using the platform. We managed to transform all of this into knowledge, to understand the occurrences, the events before and from that, and avoid numerous breakdowns. These data that the sensor passes to the platform, help us to understand what is related to vibration and act preventively. It ends up becoming very productive.”

The supervisor also reports that the used AmstedMaxion equipment, the sand mixer F1135 and the mechanical pickling machine F5226, needed balancing and that through the data that the platform emits, it is easy to identify something out of the ordinary in the machine, in order to avoid a serious break that would stop production.

After preventive maintenance on the mixer, there was a decrease of approximately 40% in the vibration of the equipment, which avoids an early wear and future stops due to unscheduled maintenance. After a period of monitoring, it was found that the vibration speed common to the mixer is 8mm / s on the horizontal axis and 4.5mm / s on the vertical axis.

“So with this insight generated, I am able to generate a preventative immediately or scheduled, so that I can make an intervention, and with that I avoid a serious breach that perhaps the imbalance would generate.”

The monitoring of the vibration variables is constant and done at a distance, in addition to the automatic “insights” that are sent by the platform. Reliability and availability have increased, and unplanned interventions in the mixer have been reduced. The replacement of parts with natural wear such as reeds and the preventive tightening in others, reduce equipment vibration and mechanical stress on critical items such as axles, bearings, bearings and motors.

The horizontal axis had peaks of vibration speed of 28.908mm / s while the axial axis reached 23.902mm / s.

Right after the preventive mechanical maintenance, we had a reduction to 10mm / s on the horizontal axis, about 65% reduction, and 13mm / s on the axial axis, approximately 50% reduction.

“Each critical asset on the monitored production line could cause major impacts on results. The average repair cost if there was a breakdown would be around R $ 2,500, with a workload of 1h30 hours and R $ 50 hourly cost.” 

Points that differentiate TRACTIAN

Another point that differentiates TRACTIAN from the others and that Tiago also highlights, is the practicality of the communication between the platform and the manager. According to him, it saves time, money and it is fantastic to receive news in a 2G / 3G way.

I have no doubt that the technology you develop is something that really supports and becomes a wild card in maintenance, regarding our support platform, it says the right thing, at the right time.

Finally, he comments that the MTTR and MTBF indexes have improved, also reducing the downtime index, thus and increasing the availability and reliability of the equipment for production. Maintenance can be scheduled in according to production, using maintenance schedules and resources more efficiently and with less impact.

To find out other points that our platform has won the hearts of maintenance managers, click here.

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Tamires Zinetti

Journalist, specialist in content for Industry and Maintenance areas at TRACTIAN, responsible for helping teams with innovative processes.

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