AIP cuts operating costs and improves efficiency and profitability for quarry operators

Global bearings suppliers NSK are constantly developing new technologies and services to meet the demands of quarry operators and equipment manufacturers for continuous operation with minimum maintenance.

The latest component in this integrated strategy is an asset improvement programme (AIP), which is aimed at end-user bearing customers who are looking for not just product supply, but for a value-added service that will help them to reduce operating costs and improve efficiency and profitability. These objectives are achieved by delivering tangible savings to assets, such as equipment and machinery, and also by improving the working knowledge of maintenance and engineering personnel.

AIP is simple to implement and can be broken down into easy-to-understand stages. This makes it logical for end users to buy into, as it shows them how NSK can add value to their businesses. The process often starts with a detailed site survey. NSK engineers visit a customer’s premises, talk to them, get to understand what their difficulty is and work out what NSK can do to support them.

As part of the AIP programme, all aspects of a company’s operations, including systems, stock, specific problem applications, lubrication, and even training issues, are audited. A lot of the time is spent questioning, understanding and listening; this is crucially important because if this stage is not right, then anything that follows will not work.

An analysis of the data acquired is then performed, which leads to recommendations for improvements. In practice, these recommendations could relate to training: about how to examine or look after bearings; how to spot failure modes; and how to handle bearings correctly – as this is one of the biggest causes of premature failure.

In addition, NSK might need to look at the lubrication of bearings; or recommend part substitution for a bearing that would work more effectively. The overall aim is to provide added value through the provision of engineering solutions that, when documented, can represent substantial savings on operating and maintenance budgets. This provides management with firm figures that give them reassurance that they have saved money and improved profitability by working with NSK.

The value of NSK’s AIP programme as a cost-reducer in the quarrying sector is evidenced by an early application of the programme, where a quarry operator was experiencing short service life on a conveyor tail drum take-up unit located in a relatively inaccessible area beneath a screen. The bearing in the take-up unit was subjected to arduous conditions due to the open nature of the operating environment. In addition, regular re-greasing was inconsistent due to the remoteness of the bearing location. These problems were culminating in failure of the bearings, resulting in conveyor downtime and consequential loss of production.

NSK inspected the application and recommended a switch to RHP triple-lip seal Self-Lube bearings and a best practice re-lubrication regime. This has resulted in significant improvements in bearing lifetime, from an average of 4 months to over two years’ continuous operation, with the AIP programme delivering savings of £4,580 per year on this one conveyor alone.

NSK UK Ltd, Northern Road, Newark, Notts NG24 2JF; tel: (01636) 605123; email: info-uk@nsk.com; website: www.eu.nsk.com