Real-time AI insight and quick team collaboration avoids downtime and lost product
Industry – Pharmaceutical //
Machine – Tablet press //
Fault Type – Bearing wear due to fluting //
Outcome – $82K in savings, including 20 hours of avoided downtime and 4.8M tablets saved
This global pharmaceutical manufacturer has been partnering with Augury for Machine Health Solutions since 2020, using end-to-end prescriptive maintenance insights to monitor production, packaging, and utility assets.
One of the many production assets being monitored is a tablet press operating in a clean room. One day last fall, Augury AI updated the machine’s health status from “monitor” to “danger” due to possible fluting in the motor bearings (damage caused by electrical discharge). Following Augury’s recommendation, the pharma company’s on-site maintenance team and vibration analyst inspected the motor and verified the issue. They determined that the machine could continue running until the next scheduled downtime period.
Augury’s algorithms analyze over 840 unique feature sets. This image depicts the velocity RMS, showing a sudden increase and rapid-cliff detection in the motor velocity trends due to a possible fluting issue.
During that downtime, about four weeks following the alert, the maintenance team removed the existing motor and replaced it with an on-hand spare. Once the Augury sensors were reinstalled and the tablet press was realigned for baseline, Machine Health data confirmed that the motor was functioning normally and the data confirmed a healthy status.
A third-party inspection confirmed Augury’s findings: the bearings were fluted due to shaft voltage, which would require repair on the opposite end drive and a new resolver.
Thanks to early detection of the motor bearing issue, which allowed the team to plan repair during a scheduled maintenance window, the company saved $82K in avoided downtime and lost product, which would have reached 4.8 million tablets.
Eager to understand the details behind the savings, the pharma company’s leadership, finance, operations, and maintenance teams worked together to quantify the benefits of this Machine Health win. Here is how they came up with the figure:
While this was a significant win for the manufacturer, the savings and benefits extend beyond the bottom-line numbers. Although not quantified, other avoided downsides include:
Keys to success
Many factors contribute to Machine Health wins, and this success story is no different. Beyond the real-time AI data itself, the following played vital roles in making this win possible:
Even more good news: Machine wins like this help with solution adoption rates, improve long term maintenance strategy, and boost team and company morale.
Learn more about how we’re helping pharmaceutical manufacturers cut downtime, improve product quality, and achieve fast value and high ROI.