Predictive Maintenance in Paper Industry | Case Studies | Infinite Uptime

1. ✓ Make In India Product USD 2 Million saved in 2 days due to prediction of gearbox breakdown. ✓ Plug & Play installation ✓ Visual LED Indicators ✓ Introduction Edge-Computing Technology ✓ Mobile based Android Application A global leading Indian paper manufacturing company specializes in technologically advanced and most eco-friendly, paper and paperboards business. The Company has the capacity to produce 300,000 tonnes of paper per annum. Need ➢ Paper production is a two-way process which involves conversion of a fibrous raw material into pulp, followed by the conversion of the pulp into paper. ✓ Configurable Diagnostics ➢ This diversified conglomerate paper manufacturing company in India faced gearbox failure which resulted into unreliable product quality and unexpected line stoppages. ➢ The Maintenance team could not detect the root-cause of failure and preventive servicing strategy did not reduce the MTBF. TAKE AWAYS FOR END-USER ➢ Remote monitoring of vibrations on the gearbox is difficult and analyzing the offline-captured equipment data is complex. ➢ The company did not want to make drastic infrastructural changes to disturb the production. © SKF Group

2. ✓ Monitors triaxial vibrations. Infinite Uptime’s Solution INDUSTRIAL DATA ENABLER (IDE) vEdge ✓ Installs in a minute. ✓ Thresholds are set as per ISO standards. ✓ Any discrepancy is notified by SMS & Emails. ➢ The IDE was installed on the input shaft of the gearbox to monitor triaxial vibrations, temperature and complementary acoustic signals in real-time. ➢ The magnetic base facilitated in quick installation on the gearbox. ➢ The thresholds were set with a mutual discussion with the Maintenance Head, the recommendation standards, and the ISO benchmarks. ➢ The IDE was configured with the software to visualize the trend on the app as well as the dashboard. ➢ The trend of the captured data was now available on the dashboard, and remotely on any android based application. ➢ Any violation of set-threshold limits would caution the Registered Maintenance authorities with SMS and Emails. ➢ The spectra of the captured mechanical data could be generated on-demand, and after every 30 minutes. ✓ Trends are displayed on the Dashboard ✓ Analysis provides actionable insights. ➢ The analysis of the trend indicated the possible causes of misbehavior of the gearbox before it actually impacted the equipment and the production. ➢ The indicatives empowered the Maintenance team to carry out remedial measures and increased the availability and reliability of the equipment. ➢ The Maintenance team could equip themselves with correct spares and service the equipment as and when required. KPI ENHANCEMENT ✓ Reduction in MTTR (Mean Time to Repair). ✓ Decrease Unplanned maintenance costs. © SKF Group ➢

3. ✓ No training required for the shop-floor team. INDUSTRIAL DATA ENABLER (IDE) vEdge OUTCOMES ✓ A change in colour of the LEDs is an indication of discrepancy. ✓ IP68 facilitates deployment in inaccessible, hazardous areas. The trend of the data captured from the gearbox in real-time shown on the dashboard ✓ Potentially predicts 80% of the faults at 20% costs. Vibration Monitoring buys you time The IDE detected very irregular FFT spectrum for the Z axis for the gearbox. The spectra displayed anomalous harmonics in the 2x and 3x regions (first even and first odd harmonics). The unusually high 1x –indicated the onset of misalignment. IDE PREDICTIONS A Very large peak in the frequency spectrum for the dominant frequency indicated a very clear misalignment and immediate need for dynamic balancing. Predicts source of failure. Ensures safety of equipment and workforce. ✓ ✓ © SKF Group

4. ✓ No need to compromise on Operational schedule. BENEFITS OF INDUSTRIAL DATA ENABLER (IDE) vEdge ✓ No charges for cloud, dashboard, additional hardware. ✓ Reduces MTTR (Mean Time to Repair). ✓ Predicted the root-cause of failure of the gearbox. ✓ Aligns Maintenance actions with business goals. ✓ Prevented the unexpected failure of the gearbox and assembly line driven by the gearbox. Phases of Mechanical Equipment Failure ✓ Facilitated quick-decision of remedial actions. ✓ Increased the MTBF. ✓ Maintained the quality of the paper produced. ✓ Assured uninterrupted operations in the plant; that confirmed production targets. ✓ The equipment history enabled Predictive Maintenance Strategy. IDE BENEFITS ✓ Prevented unnecessary storage of spares required for repairs and replacement. Increases uptime of the equipment. Digitizes Legacy equipment. ✓ USD 2 Million saved in 2 days due to prediction of gearbox breakdown ✓ ✓ © SKF Group

5. ✓ Make In India Product Wireless Condition Monitoring predicts failure of Calendar Roll Gearbox; extends the roller life and saves USD 60,000. ✓ Plug & Play installation ✓ Visual LED Indicators ✓ Introduction Edge-Computing Technology ✓ Mobile based Android Application A well-known paper manufacturing company in one of the metro cities of India, produces paper for packaging and education industry. The Company has the state-of-the art modern machinery comprising of multiple calendar machines, twin wire presses and conveyor belts that enhance the production activities. Need ➢ One of the rollers of the customized Paper finishing machine pressed the dry mesh (pulp) from the dryer and transformed it into thick sheets which were further rolled at a specific low frequency. A gearbox was used as a transmission device to complete the process. ✓ Configurable Diagnostics ➢ The failure to complete the process within a specified period caused jamming of the pulp, turning it into wastage and adversely impacting the production targets as well as decreasing the performance of the equipment. Hence monitoring the gearbox a vital equipment was essential. ➢ Besides incompletion of the process also affected the hygiene of the workforce in the plant and crossed the ethical norms set by the government authorities. TAKE AWAYS FOR END-USER ➢ Remote monitoring of the gearbox to track its operation in real-time was necessary. © SKF Group

6. ✓ Monitors triaxial vibrations. Infinite Uptime’s Solution INDUSTRIAL DATA ENABLER (IDE) vEdge ✓ Installs in a minute. ✓ Thresholds are set as per ISO standards. ✓ Any discrepancy is notified by SMS & Emails. ➢ The IDE was installed on the output shaft of the gearbox to monitor triaxial vibrations, temperature and complementary acoustic signals in real-time. ➢ The magnetic base facilitated in quick installation on the gearbox. ➢ The thresholds were set with a mutual discussion with the Maintenance Head, the recommendation standards, and the ISO benchmarks. ➢ The IDE was configured with the software to visualize the trend on the app as well as the dashboard. ➢ The trend of the captured data was now available on the dashboard, and remotely on any android based application. ➢ Any violation of set-threshold limits would caution the Registered Maintenance authorities with SMS and Emails. ➢ The spectra of the captured mechanical data could be generated on-demand, and after every 30 minutes. ✓ Trends are displayed on the Dashboard ✓ Analysis provides actionable insights. ➢ The analysis of the trend indicated the possible causes of misbehavior of the gearbox before it actually impacted the equipment and the production. ➢ The indicatives empowered the Maintenance team to carry out remedial measures and increased the availability and reliability of the equipment. ➢ The Maintenance team could equip themselves with correct spares and service the equipment as and when required. KPI ENHANCEMENT ✓ Reduction in MTTR (Mean Time to Repair). ✓ Decrease Unplanned maintenance costs. © SKF Group ➢

7. ✓ No training required for the shop-floor team. INDUSTRIAL DATA ENABLER (IDE) vEdge OUTCOMES ✓ A change in colour of the LEDs is an indication of discrepancy. ✓ IP68 facilitates deployment in inaccessible, hazardous areas. The IDE detected a rise in vibrations accompanied with a significant change in the acoustic signals. Spectral analysis of the captured data over the dashboard indicated a possibility of the surface wearing of gear teeth or a shaft misalignment resulting in increased gear mesh vibrations. ✓ Potentially predicts 80% of the faults at 20% costs. Vibration Monitoring buys you time FFT before corrective action FFT before corrective action IDE Corrective measures of oiling the gear teeth and reconsidering the shaft alignment avoided the severe breakdown. PREDICTIONS Predicts source of failure. Ensures safety of equipment and workforce. ✓ ✓ © SKF Group

8. ✓ No need to compromise on Operational schedule. BENEFITS OF INDUSTRIAL DATA ENABLER (IDE) vEdge ✓ No charges for cloud, dashboard, additional hardware. ✓ Reduces MTTR (Mean Time to Repair). ✓ Maintained uninterrupted production in the line. ✓ Aligns Maintenance actions with business goals. ✓ Prevented wastage of raw material. Phases of Mechanical Equipment Failure ✓ Saved the estimated expenses of USD 60,000 on the repairs and replacement costs of the Gearbox. ✓ Ensured a consistent operation of the plant to achieve its production target. ✓ Maintained the safety and hygiene in the plant. ✓ The equipment history enabled Predictive Maintenance Strategy. ✓ Prevented unnecessary storage of spares required for repairs and replacement. IDE BENEFITS ✓ Enhanced the life of the gearbox. Increases uptime of the equipment. Digitizes Legacy equipment. ✓ ✓ © SKF Group