Smart Performance Program: Cost Reduction through Prevention

Aluminium Norf is monitoring side trimmers by means of FAG ProCheck

Aluminium Norf GmbH wanted to ensure an optimal level of availability of its complex plant to save costs. So the company asked FAG Industrial Services (F'IS) to install a vibration monitoring system at its plant in Neuss, Germany.

The challenge consisted in the complexity of the plant: Aluminium Norf, one of largest aluminium rolling and remelt plants in the world, uses a pair of mechanical side trimmers near the end of the finishing train. The side trimmers cut off the uneven edges of the aluminium strip passing through that are inevitably produced in the rolling process. So every replacement of a bearing in these trimmers involves a considerable amount of preparatory and follow-up work. Any unexpected failure of a rolling bearing - and thus of the side trimmers - means that the whole hot rolling train must be shut down, causing enormous costs.

To minimise the risk of such a scenario happening, F'IS experts installed the FAG ProCheck online monitoring system at two pairs of side trimmers. In addition, the service company of the Schaeffler Group provides support to Aluminium Norf under a service contract. After the measuring points had been defined and the sensors had been installed, they began to send the necessary additional signals to the FAG ProCheck. These signals include the bearings' speed as well as information on whether the side trimmers are working or idle. The measured data are analysed both on location and at the certified F'IS service center. The measuring system reliably detects even the slightest irregularities. The FAG ProCheck always provides the customer with up-to-date information about the condition of its production facilities and permits predictive maintenance.

The first time the systems prevents a disruption of production due to damage to the side trimmers, Aluminium Norf will save at least EUR 80,000. From the second time on, savings will reach a six-digit amount. By comparison, the cost of one FAG ProCheck system, four sensors, consultation and initial start-up add up to under EUR 19,000.

FAG Industrial Services GmbH (F'IS)

Headquartered in Herzogenrath near Aachen, FAG Industrial Services GmbH (F'IS) offers its services, service products and maintenance training on a manufacturer-independent basis, helping customers to save on maintenance costs, optimize machine availability and avoid unexpected machine downtime. F'IS takes responsibility for Schaeffler Group Industrial's worldwide service business regarding the INA and FAG brands. In 2007, the Schaeffler Group employed a workforce of about 66,000 at 180 locations worldwide and generated sales of EUR 8.9 billion with its brands INA, LuK and FAG.

Contact

FAG Industrial Services GmbH

Sabine Drescher

Marketing & Communication

Tel. +49 (0)2407 9149-78

Fax +49 (0)2407 9149-59

E-mail: drescher_s@fis-services.de

DOC (1.73 MB)
JPG (108.34 KB)

JPG (808.69 KB)

more Press Releases

· Publications

Press Contact

If you need any further information, don't hesitate to contact us.
Press Contact