How a High-Volume E-Coating Facility Reduced Downtime with OTC’s Data-Driven Pump Condition Monitoring

OTC Industrial Technologies partnered with a manufacturing facility to find the source of their frequent pump failures that was continuously leading to unplanned downtime and costly repairs. OTC implemented a monthly service program to track bearing temperatures and vibration levels, enabling early detection of potential failures. With enhanced condition monitoring and predicative maintenance, this proactive approach reduced downtime, improved pump reliability, and allowed for faster repairs when needed.

Overview

A manufacturing facility was experiencing frequent pump failures in their production line, particularly with Gusher Pumps used in E-coat and chemical parts wash processes. These pumps operate continuously in a harsh chemical environment with minimal maintenance, resulting in costly downtime whenever a pump needed replacement.

To address this issue, the facility sought a solution to minimize equipment failures and production interruptions to reduce downtime in manufacturing operations.

• Customer: Industrial Coating Services
• Relationship with OTC: 4 Years

Challenges

The facility was experiencing excessive downtime due to recurring pump failures and the need for equipment changeouts. Since the pumps operate 24/7 and are exposed to harsh chemical environments, breakdowns occur more frequently.

Without a pump condition monitoring system in place to track performance and forecast failures, the team only discovered issues when a pump abruptly failed. Downtime had a substantial impact on the business’s ability to perform critical services for its customers.

Company management needed to improve Gusher Pump reliability, performance, and lifespan to prevent unplanned downtime and reduce maintenance disruptions.

Solution

To address ongoing pump failures and downtime issues, the facility turned to OTC Industrial Technologies.

The OTC Team assessed the company’s challenges and developed a custom industrial pump maintenance strategy designed to meet their specific needs.

1. Implement a Monthly Service Schedule - A monthly service schedule was established by OTC technicians to monitor the facility’s pumps and provide a report to the customer detailing the overall condition of the equipment.
2. Measure Bearing Temperatures & Vibration Levels - Because upper and lower machine bearing wear, and excessive vibration are two common causes of pump failure, the OTC Team began to measure each pump’s bearing temperatures and vibration levels monthly. This information was recorded for the customer.
3. Document Bearing Temperatures & Vibration Levels - Documenting these two critical equipment metrics through consistent bearing temperature monitoring and pump vibration analysis provided the OTC technicians with the information they needed to determine when an equipment failure might be on the horizon. This data gave the facility the chance to proactively address the issue before pump failure occurred. 

Based on this strategy, if bearing temperatures or vibration measurements show a significant change from one month to another, the customer is notified so a pump replacement can be scheduled to be replaced, thus reducing pump downtime and avoiding costly disruptions.

If a pump does fail, it is quickly sent to OTC’s repair facility where Gusher parts are kept on hand. OTC’s factory trained technicians quickly repair the pump and return it to the facility, expediting turnaround time. 

Results

By leveraging OTC’s monthly pump condition monitoring service to track temperature and vibration data, the facility can anticipate pump issues resulting in a significant reduction in unplanned downtime. Servicing or replacing pumps during scheduled maintenance windows eliminates the need for reactive repairs, ensuring uninterrupted operations the monthly reports provide clear documentation for ISO audits, demonstrating a commitment to quality control and efficient operations. With a reliable equipment health monitoring system in place, the facility has improved production continuity, optimized maintenance expenditures, and achieved smoother, more cost-effective operations.

Contact one of our experts today about how OTC’s monitoring industrial maintenance solutions can prevent downtime and maximize your facility’s efficiency and productivity. 

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