STEP 1
Facility review
We look at what is installed, which parameters are critical and where the losses are today.
At your facility or remote
Machine and power monitoring: equipment fails on a trend, not on a day
Vibration rises, phases drift, run hours pile up on one unit and not on its neighbour. All of it is visible weeks before the stop, provided something is watching between the shifts.
weeksof warning on a typical bearing
per unitrun hours instead of a calendar
24/7cover between shifts and at weekends
Control points
What we monitor on equipment
The parameters that, in most facilities, are either not measured at all or measured by a walk-round once a shift.
Run hoursReal load per unit, instead of a calendar-based maintenance schedule.
Vibration and amplitudeThe trend that appears weeks before a bearing fails.
Power qualityVoltage, current, power and phase imbalance, caught before a motor burns out.
Controller alarmsStatuses and faults read from the equipment's own controller.
Motor and pump startsConfirmed starts, duty cycles, and running outside the schedule.
Generator readinessFailed starts, start-up delay and fuel, so the backup is proven rather than assumed.
Unit temperatureBearings, enclosures and exhaust.
Energy per lineConsumption by shop, by line and by equipment group.
This is condition and energy monitoring, not an MES. We do not count parts, cycle times or OEE. If that is what you need, this system sits alongside one rather than replacing it: what we cover is whether the equipment is healthy, and what it costs to run.
What does an hour of downtime cost you?
A pilot on 5-10 points gives you the trend within weeks.
How it works in practice
Situation and system response
Situation
What the system does
What you get
Vibration rises on a unit
The amplitude trend is charted long before an emergency stop
Repair happens on a planned stop
Phase imbalance on a drive
The deviation is recorded and the electrical engineer is alerted
The motor does not need rewinding
A compressor runs outside working shifts
Consumption and run hours outside the schedule are visible
A standing overspend is removed
The generator is never actually tested
Failed starts and start delay are logged from real events
The backup is proven, not assumed
Proof
Screens from live facilities
Already running at
ArcelorMittal
Swiss Krono
steel pipe and railway wheel manufacturer
pig farming and food production group
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Deployments to date are largely in Ukraine.
Rollout
From pilot to full coverage
STEP 2
Pilot on 5-10 points
A gateway, sensors and meters on the riskiest zones. Installed without stopping operations.
A few hours per facility
STEP 3
Dashboards and reports
We draw up the facility plan, set the limits for each point, the alerts and the report formats.
Shaped around your processes
STEP 4
Scaling up
The same kit across the remaining zones and facilities, with a single view for the whole company.
No new approvals needed
Next step
We will find what is not being measured on your floor
Send us your equipment list. We will say which parameters we can read from your controllers and where a sensor has to be added.
- CompanyPolymetrica LLC
- E-mailsales@polymetrica.net
- Websitepolymetrica.net