PREDICTIVE MAINTENANCE

The project

A way to achieve important cost-savings

Thanks to the precise and objective follow-up of wear levels of machinery equipment, you will be able to identify the right moment of intervention. Consequently, Novexa's approach reduces breakage risks or complications (i.e. production stoppages) significantly.

These cost savings are significant in the short, medium and long-term

The main cost-saving sources are :

• Increase in the shelf life of the harness :
  Templates can quantify the shelf life of a machine objectively. A gear with a wear speed of 0,1 mm can last 5 times longer than one of the wear speed of 0,5 mm annually.
  Lubrication, hardness, pollution and operating conditions are points of improvement. Novexa will accompany you to reduce your wear levels.
• Detained profile deformation
  Profile deformation is directly linked to the destruction of the kinematic chain. A red colour code is always a source of expenses (study of more than 150 machines)
• Reduced intervention duration for bearings scrapping
  Kiln roller and trunnion bearings are subject to scrapping in order to recreate oil corners. This step is essential to avoid the risk of metal on metal contact between pinion and bearing.  Novexa has developed an on-site machining technique replacing manual scrapping.

• Controlled temperature on gear teeth
  Many tooth breakages or excessive wear can be explained by excessive wear of flanged guides. Breakages are preceded by temperature gaps on the teeth. A monthly temperature control is guaranteed within a predictive maintenance.

NOVEXA provides a unique solution in the world of gears. No other market player acts in the interests of a breakage anticipation.

• Neither crown nor tube manufacturers
• Nor lubricant suppliers

Note that your decisions are often taken under pressure of stoppages risks, which can lead to hasty decision making.

Difficulties in decision making processes

Relying on a ten-year experience in rotative equipment wear management, we have developed a considerable expertise in on-site intervention. Nevertheless wear gear management should not find its limits in (often ill-timed) interventions.
We are aware of the necessity of reducing maintenance expenses while optimizing production levels. This can be achieved through tailored control measures.
Indeed, it is often very difficult to identify the right moment of intervention, which should be neither too early (needless premature stoppage on a well functioning machine) nor too late (high breakage risk and resulting high expenses). Factors like a lack of information about real wear levels as well as limited budgets often lead to an over-use of machinery equipment.

Regarding gears, tires and bearings, established tools e.g. vibration measurement, are effective predictive tools for rotation control but are not adequate for gear itself.

Thus, an excessive vibration level entails high maintenance costs, even though 80% of cases show that the origin of the problem is solely the girth.

Thanks to our expertise, we have created a simple follow-up process of wear levels through objective measures. We generally classify wear levels according to four color codes:

We thereby consider 4 phases within the wear level :

• Green code Low wear level :                 Machinery in good conditions. No intervention
• Yellow code Progressive wear level : Follow-up / observation of machinery
• Red code Considerable wear level :    Necessary intervention, reparation
• Black code Excessive wear level :       Urgent intervention (curative approach)

In all of the plants, where the red or the black codes have been identified, stoppages and considerable immediate or planned expenses occurred. Novexa's know-how provides for solid technical solutions in order to anticipate future breakages or other damages.

Joint venture development

We are offering this simple but efficient follow-up system through a regular control of the following key parameters, checked at regular intervals :

• Profile deformation
• Wear speed
• Vibration level
• Temperature
• Fissure measurement (if necessary)

The set up of a joint venture consists in 3 steps :

1. Training sessions carried out by Novexa
Novexa will train your staff on gear maintenance tasks, the follow-up of wear levels of the harness and on the control system of rotative equipment. Your staff will thereby gain an important know-how within the control of wear levels. More

2. The Novexa tool kit
We have developed a specific tool kit containing exclusive tools (which have been created in collaboration with our research department) to efficiently carry out the measurement of your equipment. This kit is specifically tailored to every single machine, containing templates, fealure gauge and a manual. More

3. Novexa's Intranet
According to your preferences, you will have also access to our intranet, developed by our team. Thereby, entering wear level information, you will receive a quick and exact summary of your machinery wear levels. More

This continous follow-up will facilitate the decision making process for an intervention.

Novexa has always been an expert in managing wear speed. As a privileged partner in the industry, Novexa disposes of a long record of interventions regarding wear of gear, reprofiling, consulting and audit.

As of today, Novexa has developed its service range even further : our unique know-how applies to the wear of tires, alignment control measures and linked services ( bearing scrapping, welding repair etc.) as well.