Table of Contents
Client Overview
A leading automobile OEM manufacturer specializing in radiators, engine cooling systems, intercoolers, and condensers, operating four plants nationwide.
Machine Landscape
- Production Lines: 16
- Type: Specialized machines
Challenges
The client faced several challenges impacting production efficiency and costs:
- Annual spare part costs due to failure: ~₹15 million.
- Monthly breakages resulting in significant production losses.
- Time-consuming replacements requiring three shifts.
- Difficulty in maintaining problem-solving competency.
- High manpower costs associated with addressing breakages.
Approach
To tackle these challenges, noxVIEW identified critical causes of breakages, collaborated closely with the client, and implemented an IoT system for a preventive maintenance framework.
Results
The implemented system yielded significant improvements, including:
- MTBF (Mean Time Between Failures) improved by 10-15%.
- Substantial reduction in operational costs, achieving savings of ₹5 million YoY.
- Breakages reduced by 12%.
- Proactive maintenance strategies minimized machine downtime.
Conclusion
By adopting a predictive and preventive maintenance approach, the leading automotive radiator manufacturer was able to enhance operational efficiency, reduce costs, and improve overall production reliability.
