ANMAR Prevents €312,000 in Production Losses for Key Client Using ACOEM's Machine Defender Solution

Distributor: ANMAR (Predictive Maintenance Service Provider)

Industry: Textile Industry

Location: Barcelona, Spain

EXECUTIVE SUMMARY

ANMAR, a predictive maintenance specialist & Acoem’s distributor, was tasked with ensuring the reliability of a key account in the medical device and textile industry. When a fan critical to the client’s most important production line began showing severe signs of failure, ANMAR leveraged ACOEM’s Machine Defender powered by the Accurex automatic diagnostic AI, to manage the crisis. By providing precise, real-time diagnostics and actionable recommendations, they successfully guided the client through a 26-day period of intense monitoring, averting a catastrophic failure. This intervention prevented €312,000 in potential production losses, secured the key account for ANMAR, and led to an expansion of predictive services across the entire plant.

The Challenge

The primary challenge was retaining a key account by preventing the imminent failure of a critical fan on their main production line.

An unexpected stop of this production line results in losses of €500 per hour. A catastrophic failure of the fan would lead to significant, costly downtime. The situation was urgent, as initial analysis showed Stage 3 bearing damage that was rapidly progressing to Stage 4, compounded by structural resonance and looseness.

The problem was magnified when it was discovered that the backup fan was not available for immediate use and that there were accessibility issues preventing a quick replacement. This left the production line highly vulnerable and put immense pressure on ANMAR to find a solution that would keep the line running while a permanent fix was prepared.

The Solution

Using the ACOEM FALCON analyzer and the NEST VISION platform, ANMAR’s Machine Defender service implemented adaptive monitoring, intensifying checks as the fan’s condition deteriorated.

The accuracy of the diagnosis, which identified multiple combined faults (bearing, imbalance, resonance, structural rigidity), was essential in guiding the customer with confidence. This solution enabled real-time monitoring of the deterioration, appropriate recommendations (lubrication, backup repair), and root cause analysis based on high-quality data.

The Results

The intervention was a complete success, turning a potential disaster into a planned maintenance event and demonstrating immense value to the client.

ANMAR successfully kept the critical fan operational for 26 days while managing the complex repair and logistics of the backup unit. This culminated in a planned, 4-hour stop to swap the fans, after which the original fan was repaired to serve as a proper backup. The machine returned to normal function, and the client’s production was secured.

€312,000 saved in avoided production losses (€500/hour x 24 hours/day x 26 days).
€0 in waste from unplanned downtime, as the fan replacement was a planned, 4-hour event.

The Impact

The successful management of this critical event has fundamentally strengthened the business relationship between ANMAR and its client.

The project solidified the client’s trust in ANMAR, elevating them to the status of a “Technical solver reference”. The client gained a deep understanding of their machine’s condition and the value of an adaptive predictive maintenance strategy.

The success of this intervention led the client to extend the Machine Defender solution to the rest of the plant and contract ANMAR for additional services like alignments and balancing. The client is now also considering installing permanent ACOEM monitoring solutions like MVx and Sparrows on other parts of their lines.