Reliability Reinvented Through the Acoem Ecosystem in Brazil

Location: Brazil
Application: Steel Industry

EXECUTIVE SUMMARY

A leading steel manufacturer in Brazil has been relying on Acoem’s predictive maintenance technologies since 2008. What began with offline instruments evolved into a complete ecosystem of solutions designed to boost asset reliability, optimize resources, and reduce the costly impact of unplanned downtime.

The Challenge

Like many industrial players, this company faced a shortage of skilled labor, constant pressure to optimize internal resources, and the rising costs associated with unexpected stoppages. The need to monitor additional assets outside of the original inspection plan added further complexity. Without a new approach, the risks were clear:

Increased maintenance costs
Loss of technical credibility
Declining competitiveness in the steel market
Reduced margins for reinvestment.

The Solution

To address these challenges, the company expanded its predictive maintenance program by building on the Acoem ecosystem. Over the years, it renewed its portable instruments, deployed several Falcon analyzers, and implemented MV-x for continuous crane monitoring. The latest step was the adoption of Sparrow, Acoem’s wireless intelligent vibration sensor.

This combination created a unified predictive maintenance strategy where Sparrow enabled continuous monitoring of assets previously outside inspection plans, while portable and online systems provided deeper analysis of critical machines. The ecosystem’s user-friendly hardware and software ensured smooth implementation, and Acoem’s technical support gave the customer confidence to keep investing.

The Results

Thanks to this integrated ecosystem, the steel manufacturer significantly improved asset reliability and reduced the frequency of unplanned stoppages. Maintenance costs decreased as interventions became better planned, and technicians were freed from repetitive manual inspections to focus on higher-value tasks. Predictive maintenance gained greater credibility inside the organization, becoming an essential tool for both safety and efficiency.

The Impact

The benefits went beyond immediate cost savings. By adopting a complete Acoem ecosystem, the company established predictive maintenance as a strategic asset and strengthened its resilience in a competitive market. Trust in production processes increased, while the long-term collaboration with Acoem reinforced a shared vision: building a fully integrated, intelligent, and reliable maintenance environment.