Field results
Issues confirmed and documented by each site's maintenance team on Amazon Monitron deployments supported by Tactical Edge. Dollar figures are the site team's estimates.
90-day pilot
The site team estimated $409,500 in avoided cost across the five cases and 30 hours of unplanned downtime saved. Hardware and the cloud monitoring service for the pilot cost $32,000. The customer went on to deploy at scale.
| Asset | Failure | Downtime saving | Maintenance saving | Total saving | Downtime hours saved |
|---|---|---|---|---|---|
| Cooling tower fan | Drive shaft alignment | $170,000 | $30,000 | $200,000 | 11 |
| Cooling tower fan | Motor bearing | $84,000 | $70,000 | $154,000 | 17 |
| Filling line motor | Motor bearing | $30,000 | $4,000 | $34,000 | 2 |
| Hot water pump | Pump valve setting (cavitation) | $0 | $15,000 | $15,000 | 0 |
| Boiler feed pump | Pump damage (seal) | $0 | $6,500 | $6,500 | 0 |
| Total (site team's estimate) | $284,000 | $125,500 | $409,500 | 30 | |
Cooling tower fan
Provides chilled water for assembly and sub-assembly production areas
21 days from install to the high ISO alarm
A low ISO vibration alarm was present at install. Twenty-one days later the high ISO alarm fired, followed by a machine learning alarm. The technician diagnosed a motor alignment problem.
Site team's estimate: $200,000: $170,000 in lost production and $30,000 in emergency repair cost
Cooling tower fan
Provides chilled water for critical boiler room assets
Enough warning to cover a three-month replacement lead time
A high ISO vibration alarm and a machine learning alarm fired together. The team lubricated the motor right away, which kept it running while the replacement motor, on a three-month lead time, was ordered.
Site team's estimate: $154,000: $84,000 in downtime and $70,000 in emergency repair and maintenance
Conveyor belt
Carries product to the sealing assembly
30 days of monitored warning
The team watched the alarm for a few weeks, then confirmed with an ultrasonic listening tool that the bearings were at an early stage of failure.
Site team's estimate: $34,000: $30,000 in downtime and $4,000 in emergency repair and maintenance
Field results
Each one follows the same alert-to-repair workflow: an alert, a technician's inspection, a repair, and an after-repair trend that confirms the fix.
Alert: Machine learning vibration alert on a drive shaft bearing
Finding: The technician inspected the bearing and found material separation.
Alert: Machine learning temperature alert on a drive roller bearing
Finding: The technician found excessive debris built up underneath the belt drive.
Alert: Machine learning vibration alert on a conveyor gearbox
Finding: The technician inspected the conveyor gearbox and found it leaking oil.
Alert: Machine learning vibration alert on a vacuum pump
Finding: The technician checked the vacuum pump for mechanical looseness.
Alert: Machine learning vibration alert on a belt drive shaft bearing
Finding: The technician found the drive shaft oscillating back and forth.
Alert: Machine learning temperature alert on a vacuum pump motor
Finding: The technician used an infrared camera to pinpoint the source of the heat.
Alert: Machine learning vibration alert on a drive motor
Finding: Checking belt tension and alignment showed the drive pulley 3 mm off center.
The free assessment ranks your critical assets and the failure modes behind them.