Success Story
Industry: Automotive
Application: Machining Centre
Cost Savings: € 190 992
Introduction
A large manufacturer of automotive engines was having increasing reliability issues with its machining centres. This had a severe effect on manufacturing output resulting in increased costs and reduced machine productivity. Following a failed bearing analysis it was revealed that the cutting fluid was entering the bearing which was severely
affecting the lubrication. NSK proposed a sealed spindle bearing with significant improvements in bearing life.
- Machining Center Vertical Spindle
- Sealed Super Precision Bearing
Key Facts
- Machining Centre Vertical Spindle
- Malfunction of the machine due to coolant that entering the bearing
- NSK Solution: Sealed Super Precision Bearings
- Increased life-time
- Reduced down-time
- Cost saving for bearings and maintenance
Value Proposals
- Realisation of an AIP Process Map
- NSK Failed Bearing Analysis showed damage to the lubrication due to coolant entering the bearing
- NSK proposed Sealed Super Precision Bearings
- Implementation of training for the Super Precision Bearing´s mounting process
- Machine design consultancy for associated housing components
Product Features
- Non-contact seals
- Time saving: Bearing mounting time 4 × faster and contamination through poor handling eliminated
- Non-contact seals provide valuable protection; reducing raceway and ball surface wear, noise and vibration, lubricant breakdown
- No speed reduction due to non-contact seals
- Improved spindle performance
- Operates between horizontal and vertical positions
- Sealed bearings prevent grease migration in vertical spindles, promote temperature stability and provide higher accuracy machining
- Longer grease life: extended by 50% with sealed bearings
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Bearing Costs: Old bearing costs | €21.816 | Bearing Costs: New bearing costs | €7.224 | |
| Costs of lost production: Bearing life | 4 months | Costs of lost production: Bearing life | More than 1 year | |
| Engineering Costs: 54 replacements × 4 hours / replacement × € 50/h | €10.800 | Engineering Costs: 12 replacements × 4 hours / replacement × € 50/h | €2.400 | |
| Engineering Costs: Production costs: 54 replacements × 4 hours / replacement × € 1.000/h |
€216.000 | Engineering Costs: Production costs: 12 replacements × 4 hours / replacement × € 1.000/h |
€48.000 | |
| Total Costs | € 248 816 | € 57 624 | ||
Reference:SS-E-7000
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