NSK Case Study

Application

Wire Forming Production

Cost Savings: $1,288,690

A customer was experiencing repeated bearing failures on their wire drawing machinery, resulting in excessive downtime and high maintenance costs. The financial impact was significant, and resolution was urgent. Upon investigation, NSK specialists determined that the root cause of bearing failure stemmed from sealing deficiencies and compromised lubrication. A new bearing and lubrication package was recommended and tested, with results demonstrating dramatically improved bearing performance and service life.

Key Facts

Continuous wire drawing process with high loads and arduous conditions
High bearing failure rates, as many as 75 per month
Excessive downtime and high maintenance costs
Failure Analysis determination: compromised lubrication
NSK proposed a sealed full complement Cylindrical Roller Bearing filled with a Lithium Complex grease
Improved bearing performance / productivity achieved

Wire Drawing Machine

Value Proposals

Bearing failure analysis indicated that the primary cause was poor lubrication
Lubrication analysis determined that the existing graphite-based lubricant employed was not suitable
NSK proposed a trial using a specially selected Lithium Complex grease together with a sealed full complement Cylindrical Roller Bearing
Initial trials demonstrated a 40% increase in bearing life
The customer converted all of their roll assemblies over to the NSK proposed bearing / grease combination
A significant reduction in downtime and maintenance costs was achieved, resulting in a substantial cost savings

Product Features

Accommodates extremely high radial and axial loads
Advanced contact seal prevents grease leakage and ingress of water and external contaminants
Corrosion resistant phosphate coating permits use in a wide range of environments, including exposure to external environments
Simple re-lubrication – even during operation – with inner and outer ring lubrication holes and grooves
Bearings filled with Lithium Complex grease
Can be fitted with snap rings on the outer ring
Full complement
Cylindrical
Roller Bearing unit
with seals

Cost-Savings Breakdown

  Before Cost NSK Solution Cost  
  Constant failure of bearings /
75 Rolls changed per month
  Significant improved reliability /
45 Rolls changed per month
   
  0.5 hours per change /
$6,428 per hour lost production /
$241,042 per month x 12 months
$2,892,504 0.5 hours per change /
$6,428 per hour lost production /
$144,585 per month x 12 months
$1,735,020  
  378 labor hours /
$14,983 per month
x 12 months
$179,796 108 labor hours /
$4,279 per month
x 12 months
$51,348  
  Technical Support &
Engineering Time
$2,758 No Technical Support needed $0  
  Total Costs $3,075,058 Total Costs $1,786,368  
Before Cost
Constant failure of bearings /
75 Rolls changed per month
 
0.5 hours per change /
$6,428 per hour lost production /
$241,042 per month x 12 months
$2,892,504
378 labor hours /
$14,983 per month
x 12 months
$179,796
Technical Support &
Engineering Time
$2,758
Total Costs $3,075,058
NSK Solution Cost
Significant improved reliability /
45 Rolls changed per month
 
 
0.5 hours per change /
$6,428 per hour lost production /
$144,585 per month x 12 months
$1,735,020
108 labor hours /
$4,279 per month
x 12 months
$51,348
No Technical Support needed $0
Total Costs $1,786,368

Your Partner for Machine Optimization

Our AIP Added Value Program is based around a simple proposition: ‘improvement pays’. By working with you throughout the AIP Value Cycle, we will help you achieve improvements in machine reliability, productivity and performance, all of which carry a tangible and measurable cost benefit – and we have the tools to prove it! That’s what we mean by improvement pays.