Predictive Maintenance in the Automotive Industry to ensure uninterrupted operations in manufacturing plants
Goal of the company
Our client, a prominent automotive manufacturer, faced significant challenges that threatened the continuity of its operations, necessitating the implementation of an up-to-date, connected monitoring system. Among its requirements:
- Dealing with Costly Machinery Breakdowns: The client was incurring costs of €532,000 per hour due to unplanned machine breakdowns and downtime in its automotive manufacturing plants, so it was looking for a solution to improve the continuity of its operations.
- Reduction of Plant Downtime and Waste: Uncertainty regarding the status of machines caused unplanned downtime and avoidable waste, leading to significant financial burdens and compromising production results and overall quality standards.
- Optimizing Operations and Improving Competitiveness: To overcome these challenges, the client sought a solution that would reduce downtime and waste, optimize operations, and enhance its competitive advantage.
Main Scops features used
- Integrated Scops solution with IoT Measurement, Wireless Connectivity and AI-powered Data Analysis: Scops provided a comprehensive solution including Internet of Things (IoT) technology for state-of-the-art measurement sensors, a robust wireless data infrastructure and a sophisticated software system powered by the power of Artificial Intelligence. With Scops, the company implemented Smart Predictive Maintenance, addressing the need to optimize operational efficiency and maximize plant productivity.
- Artificial Intelligence Analysis of Multiple Data Points: The state-of-the-art Scops platform integrates and analyzes multiple data points, including crucial parameters such as electricity consumption, temperature variations, and machine vibration. By collecting and analyzing this vast amount of machine-generated data, Scops facilitates continuous 24-hour monitoring and predictive maintenance, helping customers reduce unplanned downtime by 40 percent.
Overview
In the highly competitive environment of the automotive industry, where every minute of plant downtime can result in considerable financial losses, our client was faced with pressing challenges that required an innovative solution to ensure uninterrupted operation in its production facilities.
By implementing Scops' Predictive Maintenance, the client achieved significant cost savings, avoiding unplanned downtime and production losses. The implementation of the Scops solution which combines state-of-the-art IoT Sensors and advanced Data Analysis via Artificial Intelligence, enabled the customer to gain a comprehensive, real-time view of machine performance, critical parameters and operating conditions. This unprecedented visibility has enabled the customer to make informed and proactive decisions regarding machine maintenance, avoiding breakdowns, unplanned downtime and optimizing resource utilization.
In addition, Scops' Predictive Maintenance has enabled the customer to predict maintenance needs in advance, enabling efficient scheduling of activities. This reduced plant downtime and optimized machine availability, ensuring continuous production flow and reducing overall operating costs.
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