Customer's Challenge
A production plant in Jurong Island, Singapore, faced recurring failures with a set of rubber extruder machines. After inspection, the machine’s OEM identified premature wear in the rotating screw and inner bushes as the cause. However, just a few weeks after replacing the worn-out parts, the machines began showing signs of failure again. Without a clear understanding of the root cause, the client implemented a temporary solution by stocking extra spare parts and replacing components preemptively to avoid unplanned downtime, while still meeting production targets.
Solution
To address the issue, Metal Machines dispatched a seasoned field service engineer to assess the machine’s condition and review the OEM’s findings. To gain further insights, the Faro Vantage laser tracker was employed to verify the extruder frame’s Geometric Dimensioning and Tolerancing (GD&T) specifications, including perpendicularity and parallelism. The laser tracker’s live data display was especially valuable for immediate adjustments during the alignment process.
The initial investigation revealed that the machine’s components were misaligned and outside the required tolerances. The site team then undertook the alignment of the extruder frame, which consists of five interdependent structures spanning over 5 meters in length. With the laser tracker providing real-time readings, the alignment was completed efficiently and with precision.
Benefits
The laser tracker enabled accurate and efficient measurement of large objects. When combined with Spatial Analyzer software, the collected data could be processed quickly, checked against GD&T specifications, and used to guide precise alignment. The entire process, from data collection to final alignment, took just four days. After monitoring the machine’s performance for six months, the client saw significant improvement and confidently re-engaged Metal Machines for further units in the plant.
By providing rapid, accurate measurements and alignment, the laser tracker solution improved machine reliability and reduced downtime, helping the client maintain consistent production.
