Manufacturing Oil Condition Monitoring Case Study
Cut oil consumption and maintenance costs by up to 30%
Tan Delta’s manufacturing and processing monitoring system helps you to cut oil consumption and maintenance costs by up to 30%. Oil changes are a significant proportion of a manufacturer’s running costs, and monitoring and servicing your machines with a limited engineering resource is a constant balance, particularly when breakdowns occur.
To be cautious OEMs prescribe aggressive maintenance schedules based solely on operating hours that ignore the actual equipment status and result in significant unnecessary maintenance and oil wastage. Tan Delta’s manufacturing and processing monitoring solution uses advanced real time oil analysis to tell you the actual status of your oil and thus when equipment maintenance is really needed. Instantly optimising maintenance programs whilst maintaining engine reliability and continuous oversight.
Case Study Summary
CUSTOMER
A UK manufacturer of copper and steel plumbing components, with a suite of dozens of stamping, pressing, machining, sorting and handling machines.
PROBLEM
Usable oil is disposed of, and the fleet sees excessive downtime due to the aggressive time-based maintenance schedule. In this environment lubricants are particularly prone to dust and swarf contamination, and rigid service intervals mean early warning signs can be missed leading to avoidable failures. The plant needs to minimise maintenance costs whilst also maintaining reliability.
SOLUTION
Each machine has been easily retrofitted with a Tan Delta SENSE-2 kit. SENSE-2 continually analyses and tracks actual equipment and oil condition, accurately informing the maintenance team when to undertake maintenance based on actual equipment need instead of operating arbitrary schedules.
RESULT
Changing to a condition-based maintenance schedule using Tan Delta has enabled the service interval to be increased from 500hrs to 663 hours, resulting in a 23% reduction in maintenance costs and oil consumption. Production stops can be minimised as the Tan Delta system will detect any equipment anomalies or contamination before damage, enabling preventative maintenance.
