Transforming Hydraulic Power Pack Operations with Accurex™ AI

Country : India

Application: Hydraulic Power Packs

EXECUTIVE SUMMARY

A leading Metal & Alloys manufacturer in India achieved significant productivity and reliability improvements by implementing Acoem’s advanced predictive maintenance solutions, powered by Accurex™ AI. By shifting from reactive to proactive maintenance using MV-X systems and Machine Condition Tracking (MCT™), the company eliminated unplanned failures, significantly increasing uptime, efficiency, and cost savings.

The Challenge

Unplanned Failures Disrupting Production

The company faced recurring failures in their hydraulic power packs, critical to their production process. Typical losses per pump failure ranged between €50,000 and €100,000, including both repair costs and induced production losses.

Critical components like pump bearings were prone to sudden failures due to the limitations of basic handheld analyzers. Without early warnings, the company suffered four major incidents annually, costing over €800,000.

This lack of predictive maintenance not only escalated costs but also jeopardized overall plant efficiency.

The Solution

Advanced Monitoring with MVX & Machine Condition Tracking (MCT™) and Leveraging Accurex™ AI for Predictive Maintenance

To tackle these challenges, the company deployed Acoem’s MV-X systems across 12 hydraulic power packs, integrating Accurex™ AI for real-time diagnostics and predictive maintenance. This advanced solution enabled early detection of wear and abnormalities, proactively addressing issues before they led to failures.

Key features of the solution included:

Real-time vibration and pressure monitoring for immediate detection of anomalies.
No false alarms – thanks to MCT
Automatic fault detection through Accurex™ AI, enhancing monitoring accuracy and performance.
A user-friendly dashboard for streamlined diagnostics and actionable insights.
Automated alerts to ensure timely maintenance interventions.

Why Acoem and Accurex™ AI?

The company chose Acoem for its ability to provide a comprehensive, integrated solution that combined the power of MV-X, MCT™, and Accurex™ AI:

Accurex™ AI: Automatic, precise fault diagnosis to minimize human error.
Intuitive Dashboard: Ensuring ease of use for maintenance teams.
Seamless Integration: Enhanced data analysis with existing systems, allowing for better decision-making.

Accurex™ Processing Inside

Our comprehensive condition monitoring solutions are IA embedded to delivers immediate results

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The Results

Measurable Reliability and Cost Savings

Immediate Impact

The very first instance was observed during the commissioning stage itself. A very high overall acceleration and Acoem Defect Factor was flagged by the commissioning engineer and automatically detected by Accurex™ AI. This first event was diagnosed as bearing damage, confirmed by Acoem Advisor experts.

Savings for this first detection: Estimated at €60,000.

Broader Outcomes

Zero catastrophic failures, preventing over €2M in repair costs.
30% reduction in downtime, equating to 250 additional production hours annually.
Enhanced operational efficiency, with increased confidence in machinery reliability.

The Impact

Building a Long-Term Partnership for Reliability

This collaboration highlights Acoem’s role not just as a solutions provider, but as a strategic partner in reliability. The company’s transition to predictive maintenance, powered by Accurex™ AI, has revolutionized their maintenance approach, promoting continuous improvement and innovation. Together, Acoem and the customer are now expanding the use of predictive maintenance across other critical assets, reinforcing their commitment to operational excellence.