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.
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.
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.
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.
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.
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.