Success Story

Industry: Semiconductors

Application: Vacuum Pump

Cost Savings: € 7 180 000

Introduction

A major manufacturer of silicon wafers for microprocessors experienced a failure on their vacuum pumps which were equipped with NSK bearings. A proactive maintenance strategy needed to be integrated. After consultation with NSK, an AIP expert visited the site to perform a complete Condition Monitoring Service review of the plant. With the support of the CMS equipment it was possible to produce a plant health map. Over a period of several months NSK was able to help the customer to devise their predictive maintenance strategy using analysis from the measurements. The customer also purchased the same CMS equipment as NSK to take readings and shared these readings with NSK for expert analysis. This resulted in avoidance of a further unplanned pump failure, which would have caused significant scrap at a very high cost.

Ebara Vacuum Pump

Condition Monitoring Service (CMS)

Key Facts

Vacuum pump for production of silicon wafers for microprocessors
A predictive maintenance strategy needed to be integrated
NSK Solution: Condition Monitoring Service (CMS) helped the customer to develop a predictive maintenance strategy
Early detection of pump problems allowed proactive maintenance and avoided failures
NSK integrated approach to both bearing specification for high technology vacuum pumps and after-care service applied
On-going support provided, together with specification of vibration analysis equipment allows future collaboration

Value Proposals

Pump failure in service resulted in significant costs and NSK were asked to investigate the cause
NSK performed a vibration analysis of the remaining pumps
Using NSK's CMS service a full review of the plant resulted in a health map
This allowed NSK to work with the customer to develop a proactive maintenance strategy
Several CMS reviews were completed which also showed trend analysis and early failure prediction
It also was recommended to monitor any pumps with high vibration levels with potential to fail so they can be replaced before failure occurs
On-going support is now in place to continue with CMS as the customer develops his own capability

Product Features

Live assessment of a machines condition and health while machine is still in operation
Predicted life of the critical components inside a machine allowing the customer to plan maintenance more accurately
Early warning of problems occurring in machinery. Condition Monitoring is the most sensitive and long reaching method of detecting the signs of machine wear
On-site support from NSK engineers
Assurance that NSK as a full range supplier can help with the provision of critical bearing and linear motion spares
Performance improvements and operational cost savings

Product Sheet >>

Cost Saving Breakdown

Before		Cost p.a.	NSK Solution	Cost p.a.
	Costs of lost production: Cost of production failure. 200 units x € 35.9k/unit	€ 7.180.000	Costs of lost production: No production failures	€ 0
Total Costs		€ 7 180 000		€ 0

Reference:SS-E-2091

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