A Major Car Manufacturer

A major automotive manufacturer faced significant maintenance challenges due to the high cost and lack of redundancy in their paint process equipment. Equipment failures in this critical process directly led to production line stoppages, causing substantial financial losses and delays.

To address these issues, 30 ADI OtoSense SMS devices were installed on critical motors driving pumps and blowers. The sensor has automatically learned the motor’s characteristics and started monitoring them. Within a month, two sensors detected anomalies in pump motors, indicating bearing issues. Maintenance personnel confirmed the anomalies and decided to replace the pumps during scheduled downtime, preventing unexpected production line stoppages. This proactive approach avoided a potential cost impact of at least $50,000 per hour, which would have resulted from unplanned downtime.

Additionally, it ensured timely deliveries to customers, avoiding further financial and reputational impacts. The manufacturer emphasized the importance of monitoring critical equipment in the paint process, as unexpected stoppages could lead to significant delays, product re-coating, manufacturing line restarts, and increased energy consumption. By using ADI OtoSense SMS, they were able to enhance operational efficiency, optimize energy consumption, and contribute to their sustainability goals, aligning with SDGs by promoting energy efficiency and carbon neutrality in their manufacturing processes.