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P-R2-M3RBF0_007

Major Car Manufacturer
Prevented $0.5M in Downtime

Real-time monitoring of temperature and electrical current in stamping line panels.

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    P-R2-M3RBF0_007

    The
    Challenge

    $1M per hour – potential revenue loss if stamping line stops

    • Stamping lines run 24/7, producing parts across the U.S. and globally
    • Each line costs $40M+, with a 20+ year lifespan
    • Older machines lacked embedded sensors → blind spots in equipment health
    • Risk of unexpected failures, costly downtime, and worker safety issues
      P-R2-M3RBF0_007

      The
      Solution

      Solution Implemented: GraceSense™ Wireless Monitoring

      Prevented $0.5M in losses within 6 months

       

      • Wireless sensors + cloud storage + advanced analytics
      • Real-time monitoring of temperature and electrical current in stamping line panels
      • Automatic alerts via email/SMS with troubleshooting steps
      • Configured so even non-engineers could respond quickly
        P-R2-M3RBF0_007

        The
        Results

        Examples of Detected Failures:

        • Robot controller cabinet overheating → door not closed properly → fixed before failure
        • Failed AC unit in control cabinet → detected early and replaced before shutdown

         

        • 14 million+ data points collected over 12 months
        • 2 critical downtime incidents prevented
          Nearly 10x ROI compared to project cost

          Expansion &
          Next Steps

          Scaling plant-wide after successful pilot

          Next Steps:

          • Expanding monitoring plant-wide: all stamping lines + hydraulic systems + conveyor belts
          • Adding vibration, fluid, and pressure monitoring
          • Exploring additional applications: assembly equipment, energy use, power factor monitoring

          Innovation Horizon:

          • Virtual channels: combine multiple inputs to reduce false alarms
          • Prognostic analytics: trending data for predictive alerts before failure occurs
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