An industrial plant in the UK was experiencing frequent bearing failures and emergency corrections in two vibrators used in material production. The manual collection of vibration data, performed monthly, proved inefficient in detecting problems on time, resulting in average costs of £102,000 per failure, considering lost production, recovery, and replacement parts.
The situation was further aggravated by the high risk of accidents and fires due to the heat generated by bearings in an advanced state of failure. This scenario not only had a significant financial impact but also jeopardized employee safety and the integrity of the facilities.
To address these issues, the plant implemented WEG's digital solutions, WEGscan 100 and WEG Motion Fleet Management (MFM), enabling the prevention of failures, cost reduction, and increased productivity.
Alarms configured using real data significantly reduced operating limits, while continuous monitoring allowed real-time control of equipment performance.
The results were remarkable: the plant managed to save approximately £510,000 in production capacity, achieving the return on investment in just one month. Additionally, the solution provided greater operational safety, reducing the risk of fires and damage to equipment and employees while increasing asset availability and productivity.
According to the industrial plant, the introduction of WEGscan 100 and MFM has revolutionized asset monitoring. Thanks to early failure detection and immediate notifications, it was possible to plan preventive interventions effectively, reducing costs and risks associated with emergency corrective failures.
About WEG's Digital Solutions
WEG Motion Fleet Management (MFM) is an integrated industrial asset management solution by WEG, combining over 60 years of expertise in manufacturing electric motors and other industrial equipment with cutting-edge technology. Comprised of software and hardware, the solution uses advanced predictive algorithms and IoT (Internet of Things) technology to monitor assets in real time.
WEGscan sensors collect vibration, temperature, and operating hours data, which is sent to a gateway. This gateway automatically transmits the information to the cloud, where maintenance teams can access it through comprehensive vibration reports in MFM.
The solution is widely used in the process and manufacturing industries, providing precise insights to improve asset reliability and availability.
With its position as one of the world's largest manufacturers of electric motors, gearboxes, transformers, drives, and other industrial equipment, WEG ensures that its customers keep their operations running longer and more efficiently.
