The Challenge: Unplanned downtime hits your schedule hard — missed production targets, crews standing around, and operations thrown into chaos. In high-volume plants, even a short stop can wipe out days of margin. The Problem with “Sensor-Only” Solutions: Other vendors install sensors, hand you a dashboard, and walk away. No one’s watching. Alarms get missed,...
Executive Summary Unplanned equipment downtime is a costly burden across industries, sapping productivity and profits. Studies show that unplanned outages consume up to 11% of annual revenues for top manufacturers (about $1.4 trillion globally). In automotive alone, downtime can cost $2.3 million per hour, and surveys find two-thirds of plants suffer unplanned shutdowns at least...
Reliability & ROI The real cost of failure is bigger than the repair invoice In today’s competitive landscape, the question isn’t if your equipment will fail, but when. Yet, the cost of a failure extends beyond immediate repair expenses. It delves into operational downtime, collateral damage to adjacent equipment, and lost production opportunities. Ask the...
Why Condition-Based Monitoring Matters Now Condition-Based Monitoring (CBM) has become a cornerstone of modern maintenance strategy. Instead of reacting to failures after they occur, facilities are shifting toward real-time visibility that identifies developing problems before they become shutdown events. MTI Wireless combines over 25 years of CBM experience with the 40+ year legacy of Motor...
Motor Technology, Inc. faced a monitoring limitation within a rewind bake oven operation. Temperature readings were confined to an on-site Human Machine Interface (HMI), providing no remote visibility or proactive alerting capability. When the oven exceeded preset temperature limits, the absence of automated alerts resulted in part damage — highlighting the need for a more...
A customer recently installed a new multi-stage industrial paint oven and sought to protect their investment from day one. To prevent unexpected downtime and maximize production uptime, they chose to implement wireless condition-based monitoring on the supply and exhaust fans. While the system was newly installed and professionally commissioned, monitoring quickly revealed a critical performance...
A manufacturing facility was experiencing recurring machine shutdowns caused by clogged oil filters. Each production line utilized two filters — a primary and an auxiliary — located in the basement. Operators had no real-time visibility into filter condition and were often unaware when a filter became restricted. As filters clogged, oil flow decreased and machines...
A food manufacturing facility leveraged MTI Wireless’s free two-week condition-based monitoring demo to evaluate risk on a 24/7 production line. With limited scheduled downtime occurring only once per month, early detection of mechanical issues was critical to maintaining output. During the demo period, monitoring uncovered a developing mechanical condition on a critical oxidizer fan motor...
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