SKF Operator Driven Reliability saves chemical manufacturer €111 000 in maintenance

The problem

A large North American chemical manufacturer needed to gain control over a succession of failure-prone vacuum pumps that were driving up maintenance costs. Company officials were convinced that Operator Driven Reliability (ODR) could help and sought an ODR supplier to pilot a programme in a critical production unit.

The SKF solution

The chemical manufacturer selected a comprehensive ODR solution from SKF combining monitoring tools and software, process implementation and extensive hands-on training. The project began with a detailed review process to establish programme goals – in this case, to double Mean Time Between Failures (MTBF) and reduce maintenance costs by 50%. SKF worked with the company to review operator routes and enable plant operators to measure the right conditions at the right intervals. The effort established a clear process to manage data and define responsibilities.

The results

By the end of the pilot, the plant quadrupled equipment MTBF, exceeding the initial goal of doubling it. Maintenance costs fell by 73%, 23% above the target of 50%. Due to the pilot’s overwhelming success, the company plans to promote the SKF solution for use in hundreds of locations globally. 

Summary of savings
  • MTBF on critical assets (before ODR):  3 months 
  • MTBF on critical assets (after ODR):  14 months 
  • Unit maintenance costs (before ODR):  €151 150 
  • Unit maintenance costs (after ODR):  €39 850 
  • Maintenance savings:  €111 300  
Note: All numbers are rounded off and based on customer estimates. Your particular cost savings may vary.
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