83 hours of lost production a quarter, about 57,000 inserts, cut by roughly 90%.
- 83 hours of lost production a quarter cut by roughly 90%
- About 57,000 inserts no longer lost
- Some months ran downtime-free
- Industry
- Foundry and casting
- System type
- Identical units, one goal
- Machines
- A 45 kW sand mixer, pumps, conveyors and more
- Period
- A quarter
A 6,000 tonne-a-year sand-casting foundry built around a 45 kW sand mixer, plus pumps, conveyors, sieves, vibro motors, exhaust fans, shot blasts and cranes.
Airborne sand, heat, impact loading and electromagnetic interference defeat conventional sensing through sensor failure, cabling and poor machine access.
Mapping load paths and drive-train mechanics against fault history showed that instrumenting under half the machines would head off around 80% of unplanned stoppages.
Nothing lives on the machine: the device reads from the cabinet, out of the sand, past the interference.
What changed
A quarterly 83 hours of lost production — about 57,000 inserts — was cut by roughly 90%, with some months running downtime-free.
Related use cases
Read the casePumping across the site under the same intelligence as the production process.
Walk the storyA month below plan, and nobody could say what to fix first.
Read the caseFour significant hot-saw faults caught between February and May, which led to a redesign of the structural frame.