Automotive Industry Predictive Maintenance | Case Studies | Infinite Uptime

1. ✓ Make In India Product Infinite Uptime’s Predictive Maintenance Solution predicts the tool change in a Stamping Press, and potentially enhances the life span of the Seyi Amino Motor ✓ Plug & Play installation ✓ Visual LED Indicators Introduction ✓ Edge-Computing Technology One of the leading two-wheeler manufacturers with technical support of 800 engineers has an investment of 1100 crores in India. With an annual capacity of 4 million two-wheelers, the company has six plants in India. One of the plants majorly contributed to the overall profit of the organization by producing fuel tanks and mud guards for the automotive. ✓ Mobile based Android Application ✓ Configurable Diagnostics Need ➢ A Stamping Press is used to manufacture Fuel tanks by stamping a hot metal sheet. ➢The 120 hp SEYI Amino Induction Motor running with a speed of 1450 RPM driving the Press facilitates stamping of approximately 4000 tanks per day. ➢ Failure of this motor not only affects production but also causes a disruption in further processes. ➢To achieve a daily production target it is extremely vital to monitor the performance of this motor. TAKE AWAYS FOR END-USER © 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 drive and non-drive end of the motor to monitor triaxial vibrations, temperature and complementary acoustic signals in real-time. ➢ The magnetic base facilitated in quick installation on the motor. ➢ 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 motor 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 rise in velocity of Y-axis captured from the drive-end of the motor in real-time shown on the dashboard . ✓ Potentially predicts 80% of the faults at 20% costs. Vibration Monitoring buys you time IDE PREDICTIONS 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). ✓ Prevented the Seyi Amino motor failure. ✓ Aligns Maintenance actions with business goals. ✓ Avoided the permanent damage to the die. Phases of Mechanical Equipment Failure ✓ Ensured consistent motor-operations. ✓ Assured safe operation of the die. ✓ Saved the repairs and replacement expenses of the motor. ✓ Suggested appropriate remedial measures to lubricate the motor and avert its failure. ✓ Offered insights into instantaneous health status of the motor and the Stamping Press. IDE BENEFITS ✓ Confirmed achievement of production target. (~ 4000 fuel tanks per day). ✓ Conserved the production downtime of approximately 25 hours. Increases uptime of the equipment. Digitizes Legacy equipment. ✓ ✓ © SKF Group

5. ✓ Make In India Product Patented end-to-end condition monitoring solution avoided failure of Dowel Milling Machine and saved USD 5000 ✓ Plug & Play installation ✓ Visual LED Indicators Introduction ✓ Edge-Computing Technology One of the largest auto components and automobile manufacturers in India with a capacity of producing 5 Million automotive per annum wanted to ensure the smooth operation of its Machine Shop. ✓ Mobile based Android Application ✓ Configurable Diagnostics Need ➢ To ensure minimized downtime and ensure safety in the plant. ➢ To monitor the Dowel Milling Machine which is involved in the critical process of cutting, deburring and precision machining. ➢ To detect the root cause of underperformance of this Machine during operation in spite of regular maintenance. TAKE AWAYS FOR END-USER © 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 bearing near the spindle and the motor to monitor triaxial vibrations, temperature and complementary acoustic signals in real-time. ➢ The magnetic base facilitated in quick installation on the equipment. ➢ 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 under-performance of the Equipment before it actually impacted 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 trend of the rise in velocity of X-axis and Z-axis captured in real-time shown on the dashboard . ✓ Potentially predicts 80% of the faults at 20% costs. Vibration Monitoring buys you time IDE 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. ✓ Pinpointed the improper tension in the belt that caused under-performance of the equipment. ✓ Reduces MTTR (Mean Time to Repair). ✓ Aligns Maintenance actions with business goals. ✓ Assured the seamless operation of the Dowel Milling Machine. ✓ Ensured consistent motor and spindle operations. Phases of Mechanical Equipment Failure ✓ Maintained the product-quality. ✓ Saved the repairs and replacement expenses (~USD 5000) of the Dowel Milling Machine. ✓ Suggested appropriate remedial measures to replace the belt and impart it with appropriate tension to ensure maximum performance of the Machine. ✓ Offered insights into instantaneous health status of the motor and the Spindle. ✓ Empowered the Maintenance team with correct equipment status and encouraged making a quick-decision. IDE BENEFITS ✓ Conserved the production downtime of approximately 8 hours. Increases uptime of the equipment. Digitizes Legacy equipment. ✓ ✓ © SKF Group

9. ✓ Make In India Product Zero interruptions in a vehicular plant paint shop saves USD 40 thousand; production target achieved 8 hours before the deadline ✓ Plug & Play installation ✓ Visual LED Indicators Introduction ✓ Edge-Computing Technology A major motorbike manufacturer manufactures about 3 million bikes annually and sells them across the globe. With its three huge bike-building plants in India, the organization covers almost 100 companies under its umbrella. ✓ Mobile based Android Application ✓ Configurable Diagnostics Need ➢ One of the manufacturing facility has a Plastic Line Top-coat exhaust line that paints the automotive components and despatches them for further assembly. This competent Line is directly associated with the efficiency of the plant. ➢ The exhaust line is powered with a Nadi blower-motor which is supported by a shaft and the Plummer block. As the block facilitates the smooth movement of the bearings and the rotating shaft, monitoring this block is essential. ➢ Malfunctioning of this line results in jamming the bearings and consequently cause the failure of the entire line. TAKE AWAYS FOR END-USER ➢24/7 monitoring this line is critical and vital. © SKF Group

10. ✓ 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 bearing near the Nadi blower-motor to monitor triaxial vibrations, temperature and complementary acoustic signals in real-time. ➢ The magnetic base facilitated in quick installation on the equipment. ➢ 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 rise in vibrations on the X and Y axis and the overall signal energy levels. ➢ The indicatives provided insights to 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 ➢

11. ✓ 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 rise in signal energy levels and the velocity in X-axis and Y-axis captured in real-time shown on the dashboard . ✓ Potentially predicts 80% of the faults at 20% costs. Vibration Monitoring buys you time IDE PREDICTIONS Predicts source of failure. Ensures safety of equipment and workforce. ✓ ✓ © SKF Group

12. ✓ No need to compromise on Operational schedule. BENEFITS OF INDUSTRIAL DATA ENABLER (IDE) vEdge ✓ No charges for cloud, dashboard, additional hardware. ✓ Predicted the failure of the Plummer-block. ✓ Reduces MTTR (Mean Time to Repair). ✓ Aligns Maintenance actions with business goals. ✓ Early detection of the breakdown of the Nadi blower-motor avoided an unplanned shutdown. ✓ Assured the seamless operation of the Plastic Line Top-coat exhaust line. Phases of Mechanical Equipment Failure ✓ Maintained the product-quality. ✓ Saved the repairs and replacement expenses (~USD 40,000) of the entire exhaust line. ✓ Suggested appropriate remedial measures to avoid the damage and stoppage of the motor. ✓ Offered insights into instantaneous health status of the Plastic Line Top-coat exhaust line. ✓ Empowered the Maintenance team with correct equipment status and encouraged making a quick-decision. IDE BENEFITS ✓ Conserved the production downtime of approximately 8 hours. Increases uptime of the equipment. Digitizes Legacy equipment. ✓ ✓ © SKF Group

13. ✓ Make In India Product Temperature & Vibration Monitoring remediation saves a major failure in the Assembly line of Paint Shop subsidizing USD 40 Thousand per hour ✓ Plug & Play installation ✓ Visual LED Indicators Introduction ✓ Edge-Computing Technology A preeminent two-wheeler company in India with a potency of supplying approximately 5 million bikes sells its product worldwide. The Company has five manufacturing plants in metro cities of the globe. ✓ Mobile based Android Application ✓ Configurable Diagnostics Need ➢ One of its manufacturing facility in India wanted to ensure the smooth operation of the Paint Shop to maintain continuity in the main product assembly line. The assembly line comprised of the 100 HP Class B motor that drove the main assembly line comprising of other vital components. ➢It was essential to monitor the motor to ensure consistent operation of the Assembly line to fulfill its production target. ➢General maintenance involving cleaning, lubrication, tightening of the screws did not ensure uninterruptible functioning of the line. TAKE AWAYS FOR END-USER ➢The Company preferred empowering their Maintenance team with a Remote Vibration Monitoring tool rather than overloading them to assure a seamless operation in the Paint Shop. © SKF Group

14. ✓ 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 drive and non drive end of the motor to monitor triaxial vibrations, temperature and complementary acoustic signals in real-time. ➢ The magnetic base facilitated in quick installation on the equipment. ➢ 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 rise in temperature on the motor. ➢ The indicatives provided insights to 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 ➢

15. ✓ 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 rise in temperature on the drive end of the motor captured in real-time shown on the dashboard . ✓ Potentially predicts 80% of the faults at 20% costs. Vibration Monitoring buys you time IDE PREDICTIONS Predicts source of failure. Ensures safety of equipment and workforce. ✓ ✓ © SKF Group

16. ✓ No need to compromise on Operational schedule. BENEFITS OF INDUSTRIAL DATA ENABLER (IDE) vEdge ✓ No charges for cloud, dashboard, additional hardware. ✓ Predicted the inappropriate usage of lubricant to lubricate the motor. ✓ Reduces MTTR (Mean Time to Repair). ✓ Aligns Maintenance actions with business goals. ✓ Notifications of unexpected rise in temperature and remedial measures suggested prevented the damage to internal motor windings. ✓ Enhanced the motor life by 50%. Phases of Mechanical Equipment Failure ✓ Assured the seamless operation of the Paint Shop. ✓ Conserved USD 40,000 per hour for non-productivity. ✓ Saved the asset repairs and rebuild of USD 6000. ✓ Prevented rejection of approximately 1440 components and consequently affected the production of at least 100 vehicles. IDE BENEFITS ✓ Conserved the production downtime of approximately 100 manhours. Increases uptime of the equipment. Digitizes Legacy equipment. ✓ ✓ © SKF Group

17. ✓ Make In India Product Plug and Play Predictive Maintenance tool prevents failure of Exhaust Fan and saves USD 45 Thousand in Metal Paint Shop. ✓ Plug & Play installation ✓ Visual LED Indicators Introduction ✓ Edge-Computing Technology With its head office in India, an automotive company has a potential of producing 4 million wheelers per annum. The public sector-oriented organization has 5 manufacturing plants and a human asset of around 25000. ✓ Mobile based Android Application ✓ Configurable Diagnostics Need ➢ One of the Metal line Paint shops which is well-ventilated has the potential of painting approximately 350 vehicles in a day. ➢ The inhouse condition monitoring team schedules periodic maintenance to prevent the shutdown of the plant. However, it was noticed the exhaust fan used in ventilation often operated in a disturbed manner causing unhygienic conditions for the workforce and an increase in the cure time of the vehicles. ➢Regular and precautionary maintenance failed to improve fan efficiency. Hence a quick-solution to detect the cause of the lowering performance of the fan and find the root cause of its deterioration was required. TAKE AWAYS FOR END-USER ➢The Company wanted to investigate without compromising the infrastructure, ensuring the safety of the workforce and also sustaining consistent plant operations. © SKF Group

18. ✓ 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 drive end of the motor to monitor triaxial vibrations, temperature and complementary acoustic signals in real-time. This motor powered the Exhaust fan. ➢ The magnetic base facilitated in quick installation on the equipment. ➢ 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 rise in temperature on the motor. ➢ The indicatives provided insights to 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 ➢

19. ✓ 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 rise in vibrations on the drive end of the motor captured in real-time shown on the dashboard . ✓ Potentially predicts 80% of the faults at 20% costs. Vibration Monitoring buys you time IDE PREDICTIONS Predicts source of failure. Ensures safety of equipment and workforce. ✓ ✓ © SKF Group

20. ✓ No need to compromise on Operational schedule. BENEFITS OF INDUSTRIAL DATA ENABLER (IDE) vEdge ✓ No charges for cloud, dashboard, additional hardware. ✓ Predicted the unbalance of the Exhaust-fan . ✓ Reduces MTTR (Mean Time to Repair). ✓ Aligns Maintenance actions with business goals. ✓ Notifications of unexpected rise in vibrations and remedial measures to clean the fan blades confirmed the regular fan operations. ✓ Ensured safety and hygiene of the plant . Phases of Mechanical Equipment Failure ✓ Empowered the optimum utilization of the Exhaust Fan. ✓ Maintained consistency in the operations of the Paint Shop. ✓ Saved Asset repairs and rebuild of USD 45,000. ✓ As the Exhaust fan provides early warning, strategy to implement predictive maintenance after approximately 45 days exclusive of the maintenance has increased the MTBF. IDE BENEFITS Increases uptime of the equipment. Digitizes Legacy equipment. ✓ ✓ © SKF Group