How others are winning with predictive maintenance
Gerdau, a leading steel manufacturer, was looking to reduce their annual maintenance spend while also improving productivity, thus targeting margin improvements within their manufacturing operations. Gerdau partnered with us to implement some of our industrial solutions, including Asset Performance Management (APM) and Historian, as well as leverage our Industrial Managed Services for remote monitoring—allowing them to focus on their critical subset of assets using predictive diagnostics. This technology enabled Gerdau to model their expected performance of each individual asset and its failure modes against actual conditions of various measurement points on an asset or system. This leads to early identification of issues to allow significant time to plan the appropriate PM activities to avoid functional failures. As a result, Gerdau had two major “catches” in the first 6 months of their deployment, helping them to avoid 130 hours of downtime in their Sinter plant. They estimate their annual savings from their new capabilities to be $4.5 million per year and the ROI payback on the project is only 8 months.
And this is only one example. The steel industry has a lot to gain with the adoption of digital mill technology to help improve maintenance outcomes. The industry’s unique growth levers make the it ripe for improvement and digital transformation can help them solve their preventative maintenance problems.
To learn more about how GE Digital can help you improve your mill productivity and cost per ton, visit our steel industry webpage.