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Lost production, unplanned maintenance, lubricant disposal, asset devaluation, and potential health and safety issues. Sometimes, these problems and their associated costs can all be traced back to one cause: bearing failure. The NSK Added Value Asset Improvement Programme (AIP), can help you to choose the right bearing with the right specification, to minimise bearing failure, optimise productivity, and reduce costs.
Identifying an efficient bearing solution is complex. It needs expert knowledge, experience, and a carefully planned approach to ensure increased productivity of machines and plant. The NSK AIP Value Cycle is a standardised, tried, tested and proven process, based on best practice and easily applied to your applications and processes.
Sometimes problems can go undetected for years: driving up costs and reducing profitability. Identifying the factors that contribute to high production costs takes an expert eye for detail.
NSK experts look at your manufacturing process and choice of bearings, to assess the areas likely to offer you the best returns. This Process Mapping approach – targeted at your production line, stores, or workshop environment – will produce a comprehensive review highlighting opportunities for improvement.
Based on the plant and machine condition data collected, NSK can recommend the optimum bearing solution for you. They can also provide information on machine component design, available part numbers and running conditions. This type of Application Review can support machinery upgrading or redesign, and also helps with conversion of OEM-specific part numbers.
Where bearings have worn prematurely or failed there are usually several reasons. Using state-of-the art bearing failure analysis, lubricant analysis and dimensional measurement equipment, NSK can identify the root cause of problems and make recommendations for improving bearing choice and machine design.
NSK’s worldwide expertise covers many industries and sectors. But you don’t have to rely on it alone. NSK also offers training to enable your own engineering team to strengthen their bearing knowledge, tailored to your needs – often based on the information gathered during Process Mapping.
Whether that’s bearing fitting and maintenance, diagnosing failure modes or selecting the best bearing specification, NSK training options can help you to develop in-house expertise to reduce your bearing-related costs.
So whether you’re experiencing unplanned maintenance issues, or you want to train your production and maintenance teams in new skills, the NSK Added Value Asset Improvement Programme can provide the bearing engineering expertise you want to acquire. And save you time, money, and energy, reducing your overall total cost of ownership.
...was experiencing repeated failures on a fully-mechanised bolting machine, used underground for rock reinforcement. The harsh environment, with exposure to water and abrasive particles, was resulting in a service life of just two months for deep groove ball bearings in the machine’s gear mechanism.
NSK assessed the situation and found hard contaminants entering the bearing were the cause of failure. A trial with NSK Molded-Oil bearings resulted in immediate improvement and 300% longer life for both the bearings and gears. The resulting cost saving was over £12k p.a.
...had problems with chain conveyors equipped with tapered roller bearings. In tough operating conditions with production dust and a high shaft temperature, the bearings failed several times a year, causing additional maintenance costs and unplanned stoppages.
The customer required at least 12 months’ operation between planned maintenance periods. NSK discovered that plummer blocks from both sides of the shaft lacked a free-end system – potentially shortening bearing life. Installing SNN Series Plummer Blocks equipped with Spherical Roller Bearings, and with increased radial clearance and additional heat treatment, enabled problem-free operation until scheduled maintenance, and saved £7k p.a. on downtime and maintenance.
...was experiencing repeated bearing failure on their grain stirrer application in germination vessels. Frequent bearing replacement was resulting in high costs and loss of production. NSK reviewed the application and recommended a Spherical Roller Bearing with NSK’s Super Wear Resistance material.
The bearing change produced a 400% increase in bearing life and a reduction in unplanned downtime –ultimately saving the customer £54k p.a.
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