Scrapping Wastage Costs With Senseye

By Jonathan Bonner, pre-sales engineer at Senseye

The costs of binning faulty products or reworking them can be huge. Senseye can help manufacturers make substantial gains by optimizing not just your machinery but your products - consigning most scrap to the scrapheap.

You might well know that Senseye PdM insights can transform the efficiency of your machinery and assets. Our customers usually achieve a return on investment in just three months.

What you may not know is how these insights save you even more by making sure that products are right too - potentially saving hundreds of thousands or even millions of dollars a year.

Optimizing products can be a serious business

Take this example. In the time it takes to read this sentence, 30 meters of sheet steel - a third of a football pitch - will roll off just one line at a top UK steel producer.

Imagine the sheets are in some small way faulty, say 2mm too thick. And that it takes half an hour to notice. That half-hour leaves 5.4km of sheet steel to be scrapped or reworked.

Either way, the line hast to repeat its work. Our research suggests the costs of this lost half-hour, depending on the industry, are between £5,000 at the very lowest, and £1.75m at the top end.

If it took three days to notice, the costs are crushing.

If the pieces have to be scrapped, there are lost material costs to be added to the bill. And with more and more producers and customers cutting out stock storage by using just-in-time delivery, orders may well be late and customers seriously inconvenienced.

This is an area where Senseye can provide transformative help. Our Predictive Maintenance insights, provided by Senseye PdM, into machines and robots allow us to tell you when they need maintenance and warn if they are likely to fail.

But they also let you know in the finest detail if the products rolling off the lines are right by alerting producers to the smallest changes in machine condition indicators. These give early warning of potential problems with the product.

Every manufacturer I've worked at or with has robust product-checking. Usually, this takes place through periodic sampling. But Senseye technology goes very much further.

Let me explain how:

  • Minimizing scrap or reworking: Senseye PdM gives indications of likely problems in real-time - allowing issues to be dealt with immediately (before a run of a faulty product has been completed) or the problem identified through sampling.
  • Advanced diagnostics get machines working again fast: Senseye PdM can point you to exactly where, why and how things are going wrong in the process, cutting lengthy downtime while diagnosis takes place.
  • Warranty claims: Senseye PdM can showcase precisely what went wrong, helping you claim against warranty if you have serious problems.
  • Early warning of potential problems: Senseye PdM will give notice of issues that could affect product quality before it reaches the stage where the product is compromised or degraded.
  • Minimizing customer rejections: With traditional sampling methods, even robust ones, sometimes products get through to customers, which they do not deem up to specification and therefore reject. The advances above mean this is far less likely when Senseye PdM is being used.
  • Scanning for problems in many different ways: We achieve these kinds of results because of the range of data we collect and analyze using our unique machine-learning. This includes start-up currents, cycle times, temperature, gauge, torque, voltage, current, speed, vibration, and oil levels.

We have provided these insights for machines, some of them up to 60 years old, at companies in a wide range of industries.

One of them is the large steel producer mentioned at the start. It never produced 5.4km of waste sheeting - it was using Senseye PdM.

Want to find out more about how Sensey PdM can help optimize maintenance spending and boost productivity? Check out our white paper ‘Harness the Power of Prediction’ or book a demo of Senseye PdM today.