Foundry equipment diagnosis system
Efficient planning of preventive maintenance based on effective diagnosis.
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The challenge
One of Japan’s largest automobile manufacturers wanted to improve their factory maintenance procedures to reduce the production loss through breakdown in the assembly line and consequently unscheduled repairs.
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The existing maintenance policy was to react to breakdowns. They wanted to substantially increase the uptime of the assembly line. The company needed a system that would warn them ahead of possible breakdowns.
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The solution
Omron designed a diagnostic system based on analysis of data collected from production line machines via vibration sensors. Omron provided a turn key solution for this system. Statistical analysis of the results indicates the deterioration of the equipment.
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This information enables the maintenance department to plan and organize work efficiently. The system monitors all machinery simultaneously, and consequently, the vibration data is straight forward. Data is used to show tendencies. If machinery is found to be in the ‘danger zone’, a further system is employed to supply more details so that a judgment can be made when to initiate corrective maintenance.
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Added value
Although the system Omron designed was very cost-effective, it fulfilled all expectations. The system configuration enabled the complete set of factory equipment to be effectively monitored. Maintenance work was now planned not just reactive.
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