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GE Digital
IIoT Service

Gerdau: Increasing Productivity With Predictive Maintenance

$ 4.5 million

In annual savings

8 months

Estimated ROI

Introduction

Company

Gerdau

Products

Historian

Product Categories

Predix Asset Performance Management

Challenge

Gerdau, headquartered in Brazil, is the largest producer of long steel in the Americas. In recent years, its production capacity has been growing much faster than steel consumption, putting pressure on overall prices and negatively impacting its margins. Looking to stay competitive and protect profitability, Gerdau decided to transform its enterprise asset strategy by reducing its annual spend on maintenance and improving overall predictive maintenance and asset productivity.

Solution

Gerdau partnered with GE Digital’s Customer Success Services to undergo a digital transformation. This combination of world-class services allowed Gerdau to quickly and effectively implement GE Digital's solutions—including Asset Performance Management (APM) and Historian—across multiple sites.

 

The company specifically enlisted in GE Digital's Support Services and Industrial Managed Services to help successfully accelerate the realization of software-enabled benefits across the organization. The Customer Success Manager worked side-by-side with the company to understand the business and align solution capabilities with Gerdau’s specific needs—and create and execute a plan to reach its desired outcomes. Meanwhile, the Managed Services team remotely monitored assets for abnormalities, avoiding unplanned downtime and reducing maintenance costs. To ensure continuity of operations, GE Digital’s Support & Maintenance team proactively handled bug fixes and software updates to keep software secure and cutting-edge.

 

Results

After partnering with the GE Digital, Gerdau expects to get a return on investment in just eight months. Through GE Digital’s Managed Services team, the steel producer identified two major abnormalities, avoiding over 130 hours in unplanned equipment downtime on the first monitored assets. Gerdau also expects to save upwards of $4.5 million annually, with an initial investment of under one-third of these expected savings. 

 

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