In any industry, there is always the worry of production shutdown leading to profit loss. This can happen due to any number of factors, but in the case of this particular client, there was the potential for machine degradation to lead to long-term downtime.
In dealing with this, the client’s team realized that fixing this issue could still lead to extensive downtime, along with replacing multiple parts.
The client tapped into multiple teams with a multi-faceted need that would require a balance of priorities.
The most significant goal was to find a way of replacing this degrading bearing while minimizing the downtime and loss of profit.
However, this solution also needed to meet the following criteria:
- The shaft must remain stationary throughout the job
- Standard extraction methods are not applicable
- Cutting and heating tools should not be used
- Design details of the gearbox are missing
On top of all this, it was obviously expected that any method put forth would lead to a bearing replacement with long-term potential.
THE WAJAX SOLUTION
Wajax’s solution was in competition with three others, and as such, needed to be as close to perfect as possible. Thanks to our outstanding IP and ERS teams, it was, and ultimately beat out the competition.
Our team’s plan of attack allowed the client to approach and fix the bearing from outside of the finishing mill, where other proposals involved interior access, as well as the replacement of multiple shafts, creating the potential for interior gear box damage.
Ultimately, our Wajax experts brought a solution that fit parameters, achieved all potential goals, and kept downtime to a minimum!
This project utilized the minds and collective expertise of multiple Wajax teams, showing off our true ‘One Wajax’ capabilities.
In terms of the client, the development and undertaking of this plan led to only 39 hours of downtime, and by the client’s own calculations, saved 3.5 million in costs and potential losses.