MTI Wireless Case StudyMaximizing Demo Benefits

Description of the image In this case study, we reveal the power of utilizing a free 2-week demo of our wireless condition-based monitoring system in a food manufacturing facility. This innovative approach allowed the facility to proactively detect potential equipment issues before they escalated into catastrophic failures. Delve into how this technology not only increased productivity but also led to substantial cost savings, revolutionizing their operations and paving the way for a more efficient and resilient manufacturing process.

Background and Context:
A food manufacturing company sought to improve its production line monitoring capabilities. The production line operates 24/7 to meet high product demand, with scheduled downtime for maintenance occurring only once a month. To explore the benefits of wireless condition-based monitoring, the company agreed to a two-week free demo on two selected motors in the production line.

System Description:
The demo system featured four dual-axis sensors designed to measure velocity, acceleration, and temperature. These sensors transmitted data to a controller every 10 minutes, which was then sent to a secure website for further analysis and trend monitoring.

Implementation Process:
After discussing the system capabilities with the client, we installed the four sensors on two oxidizer fan motors. The installation took under 10 minutes, followed by a demonstration of the secure website and data access. We also set ISO alarm parameters and informed the client that we would monitor the data and provide recommendations after a few days.

Results and Outcomes:
Upon analyzing the data trends over several days, we noticed that the acceleration levels for one of the fan motors were alarmingly high. We suggested that the client lubricate the oxidizer fan motor bearings to reduce these levels. While an initial decrease was observed, the acceleration levels soon began to rise again. We alerted the client to the potential risk of catastrophic failure, leading them to replace the motor. This action significantly reduced acceleration levels and averted a potential loss of $20,000 in product and additional downtime costs.

Lessons Learned and Best Practices:
This case study demonstrated the importance of real-time monitoring for early detection of potential equipment failures. By adopting wireless condition-based monitoring systems, manufacturing facilities can proactively address issues, optimize maintenance schedules, and minimize downtime.

Impressed by the effectiveness of the demo system, the client decided to invest in a custom-built wireless condition-based monitoring system for the entire production line, resulting in increased operational efficiency and cost savings.