MVS REALTIME 4.0

Introduction

An Indian multinational company founded in early 1960s is involved in automotive, power, oil, gas, construction, mining and aerospace industries. With its manufacturing plant in Pune, the company is engaged in steel forgings and finished machined components.

Executive Summary

The company has a huge Forging Press with a capacity of 5000 Tons, for closed and open die forgings. The Press forges the metal by subjecting it to heavy pressure between dies.

Challenge

The press had a frequent breakdown adversely affecting the loss in production and manpower. The Company wanted a tool to predict the breakdown and schedule maintenance.

IDE predicted Pitman breakage and saved a $ 1.2Million a day.

The IDE predicted the breakdown of the Ram on the press machine 5 hours in advance.
120 machine hours were saved
Production cost of $40M were saved for a month.
A Million $ life of the operator was saved.
Suggested corrective measures resulted in more availability of the machine.
Predictive maintenance could be scheduled
Spare parts and wear and tear of the Press was saved.

Solution

IDE patented by MVS REALTIME 4.0, a plug and play, remote monitoring and scalable device was easily installed on the ram. The IDE began its monitoring the instance it was installed. It captured the vibrations and analyzed them for any discrepancy. Every minor variation in the vibrations was detected and notified by an email or SMS. Moreover, the FFT analysis of the vibrations also recommended the corrective measures to be taken, resulting in more availability of the machine and lowering the breakdowns.

Solution Images

Pitman Left X Velocity

Pitman left Y velocity

Pitman Left Z velocity

Temperature

Noise

BHARATFORGE