AssetWatch Enables Grocer’s Transformation To Proactive Maintenance Across All Food Production Divisions
The Challenge
A leading regional North American grocer with self-manufacturing in bakery, snacks, dairy, and fresh foods, faced production challenges due to unplanned equipment failures and pressure on their burdened maintenance staff.To solve these issues, the grocer needed an industry 4.0 enterprise condition monitoring solution that would provide predictive maintenance insights, eliminate unplanned downtime on all rotating equipment across their diverse manufacturing footprint, and enable their maintenance and reliability teams to embrace new technologies that would increase efficiency and enable the transformation of their maintenance program from reactive to proactive.
The Journey
To begin their journey into Industry 4.0-enabled condition monitoring, the grocer appointed an Equipment Reliability Engineer as their internal program manager tasked with evaluating available solutions and conducting a proof of concept. After comparing solutions, they chose a $199 no-risk 30-day trial with the AssetWatch end-to-end vibration/temperature condition monitoring solution, powered by AWS.
The white-glove solution proposed by AssetWatch simplifies predictive maintenance by including all sensors/networking hardware, system installation and ongoing maintenance, cloud-based software, unlimited user licenses, robust AI fault detection capabilities, and a dedicated Condition Monitoring Engineer (CME) providing prescriptive maintenance recommendations as needed, avoiding alert fatigue created by comparable systems.
Rapidly deployable across the enterprise by AssetWatch’s team of expert field technicians, the solution is delivered as a SaaS model with simplified pricing based on the total number of sensors, requiring no CapEx and no upfront costs.
During the proof of concept at a selected snack facility, the customer saw immediate value and reduction in downtime from the AssetWatch solution. In addition, the maintenance staff was provided enough warning from AssetWatch to plan and schedule maintenance, moving them from reactive to proactive. After completion of the trial, the grocer subscribed at the facility and expanded the AssetWatch solution into bakery, dairy, and recently the fresh divisions. In addition to vibration/temperature monitoring, the grocer added AssetWatch’s oil analysis offering to gain additional machine health insights into critical gearboxes, compressors and hydraulic systems.
The grocer has embraced AssetWatch as its enterprise condition monitoring platform and is now eliminating downtime in eight production facilities. Showcasing the shared success, the facility growth has mirrored the engineer’s rise to Reliability Engineering Manager, now overseeing the reliability efforts for all production sites. Ultimately, the plan is to roll out AssetWatch into all remaining facilities and integrate the AssetWatch data into the grocer’s CMMS.
Reliability Engineering Manager
Critical Auger Save
In one case, AssetWatch AI identified significant vibration that quickly developed on a potato hydrolift auger. The dedicated AssetWatch CME inspected the data, noted resonance at the speed of the slow-speed motor output shaft, and issued a prescriptive maintenance recommendation for the customer to inspect the auger and its motor. The customer found the equipment to be shaking and out of centerline. The customer corrected the centerline fault before catastrophic failure, preventing an estimated eight hours of unplanned downtime.
AssetWatch partnered with AWS to provide the scalability and reliability needed to support a serverless architecture. With a robust suite of services tailored for data ingestion, processing, and machine learning, AWS enables AssetWatch to seamlessly scale sensor data and deliver predictive insights to manufacturing companies. AWS infrastructure reduces operational overhead and allows AssetWatch to focus on innovation to drive value to our customers. Additionally, AWS’s strong security framework and global infrastructure ensure the resilience and compliance required to support mission-critical manufacturing operations at scale. This partnership positions AssetWatch to accelerate growth while maintaining the highest levels of performance and reliability.
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