Press line uptime rose from 71% to 84% in 12 weeks
How a metal stamping plant caught worn bearings before they stopped a line, with vibration sensors on six presses and one dashboard for every shift.
Talk about your lines →
1.Case at a glance
| Customer | Metal stamping plant with 12 press lines |
|---|---|
| Lines | Press lines 1–6 · the same parts and shift pattern before and after |
| Applied | VS-40 vibration and temperature sensors on 6 press drives · LM-1 line dashboard |
| Measured | 12 weeks before and 12 weeks after · 3 shifts a day |
2.Presses stopped without warning
On the six press lines, nobody knew a press was in trouble until it stopped. Maintenance found worn bearings with the line already down, and a repair took most of a shift.
Each line kept its own paper log, so nobody could see which press stopped most often or why.
3.A sensor on every press drive and one screen
We fitted VS-40 sensors to the gearbox and main bearing of each of the six presses. They report vibration and temperature every 10 seconds.
The LM-1 dashboard shows each press as running, idle, or stopped, and alerts maintenance when vibration goes above a set limit.
Operators pick a stop reason on a tablet at the line, so the weekly report shows which press stopped and why.
4.What changed
| 4.1Higher uptime | Average uptime on the six lines rose from 71% to 84%, measured with the same parts and shift pattern. |
|---|---|
| 4.2Repairs planned ahead | After vibration alerts, maintenance replaced four bearings during planned stops instead of after a breakdown. |
| 4.3One record of every stop | Every stop now has a reason code, and one weekly report replaces six paper logs. |
Measured on press lines 1–6
71%
average uptime before (12 weeks, 3 shifts)
84%
average uptime after (12 weeks, 3 shifts)
13
higher uptime on the same lines
29 → 11
unplanned stops per month
5.Used on these lines
| Product | Description | Specifications |
|---|---|---|
| VS-40 vibration and temperature sensor | A magnetic-mount sensor that reports vibration and temperature through a wireless gateway. |
|
| LM-1 line dashboard | A browser dashboard that shows press status, alerts, and stop reasons by line and shift. |
|
| Install and training | We fit the sensors during planned stops and train each shift on the stop codes. |
|
6.Questions about this case
6.1Do the sensors need wiring into the press controls?
No. VS-40 sensors mount with magnets and send data through their own wireless gateway, so the press controls stay as they are.
6.2Will our plant see the same uptime gain?
It depends on your machines, parts, and how you log stops today. We monitor two machines for four weeks first and share what we measure.
Plant monitoring desk
- plants@example.com
- Phone
- +1 555 0164
- Hours
- Mon–Fri 8:00–17:00