Improved operational effectiveness across industries.

Industry: Aerospace

Problem: A collision event initiated an accelerating spindle bearing degradation, putting production and quality at risk of unexpected failure.

Solution: IPercept’s continuous monitoring detected the defect and tracked the degradation over weeks. The customer used this insight to schedule a proactive spindle bearing renovation before failure occurred.

Impact: Prevented downtime and made component renovation (instead scraping) possible. Estimated financial impact: 70,000–90,000 EUR.

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Industry: Automotive

Problem: Heavy duty production in a roughing operation overloaded machine tool axes introducing backlash.

Solution: IPercept’s Loop Test-cycle identified gradual loss of preloading in ball-screw nuts of two linear axes due to heavy duty production. Repairs were scheduled two months in advance to avoid unexpected breakdown. The user verified findings on loss of backlash with ballbar test as well.

Impact: Prevented loss of machining accuracy and avoided unplanned downtime on a bottleneck machine. Estimated savings: 103,000–129,000 EUR.

Industry: Equipment manufacturing

Problem: Chip contamination under the shield of linear axis.

Solution: IPercept identified the wear progression over weeks. The frequency of axis cleaning was increased slowing down the wear progression and to extending the lifetime of the machine. Impact: Prevented premature replacement of carriages and unnecessary planned maintenance. Savings estimated at 10,000–20,000 EUR.

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Industry: Automotive

Problem: Contamination in the lubrication system.

Solution: The IPercept monitoring system alerted the customer and corrective lubrication measures were immediately implemented. Later the lubrication cycles were optimized to sustain the improved state.

Impact: Extended component life, prevented costly replacements, and avoided unplanned downtime. Estimated savings: 70,000–90,000 EUR.

Problem: Defect in guide rail has been escalating over normal utilization.

Solution: Already after deployment the IPercept system diagnosed an existing degradation on the rail, that was present since before the monitoring started. The degradation slowly escalated over time, but required no replacement for over a years time. Proactive replacement became necessary to eliminate the risk of quality deviations.

Impact: Prevented scrap and rework, while being able to schedule maintenance during already planned time window. Estimated value: 48,000-59,000 EUR.

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Industry: Automotive

Problem: Contamination in the lubrication system.

Solution: The IPercept monitoring system alerted the customer and corrective lubrication measures were immediately implemented. Later the lubrication cycles were optimized to sustain the improved state.

Impact: Extended component life, prevented costly replacements, and avoided unplanned downtime. Estimated savings: 70,000–90,000 EUR.

Industry: Equipment manufacturing

Problem: A sudden localized defect emerged on the drive-side bearing of one of the linear axes, due to a collision. The severe defect could have propagated further to other components in the feeddrive.

Solution: The defect was identified via IPercept system alerting the maintenance team to inspect and replace the bearing. No damage was found in other components, but the early alert prevented further escalation. Later part inspection identified that the machine started to produce scrap after the collision (high load intensity event).

Impact: Prevented large volume scrap production. Avoided fault escalation. Estimated impact: 150,000-180,000 EUR saved.

Industry: Automotive

Problem: The customer lacked objective data to prioritize which spindle required replacement first. Risk of premature or delayed maintenance existed.

Solution: IPercept benchmarking identified one spindle showing early degradation. Maintenance was scheduled for it first, avoiding unnecessary replacements for the other spindles.

Impact: Downtime avoided (315 hours) and warranty claims supported. Estimated financial effect: 101,000 EUR.

Industry: Aerospace

Problem: Localized defects in axis guideways carried a future risk of worsening. Replacement requires extensive planned downtime. Without monitoring, escalation could trigger expensive unplanned downtime.

Solution: Defects were continuously tracked by the IPercept system, and later inspections confirmed precise positions, validating the insights.

Impact: Maintenance could be delayed until summer maintenance window, avoiding premature action. Estimated savings: 20,000–30,000 EUR.

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Industry: Defence

Problem: Certain RPM settings caused excessive vibrations, threatening to shorten subsystem life and increase maintenance frequency.

Solution: IPercept analyzed machine signals and recommended optimized RPM settings, reducing vibrations.

Impact: Extended subsystem lifespan and avoided early replacement. Estimated savings: 25,000–30,000 EUR.

Industry: Automotive

Problem: Degradation in the axial mounting began spreading to other parts of the drivetrain assembly. Ball-screw replacement could not restore the health state of the machine.

Solution: After a necessary ball-screw replacement, IPercept continued monitoring and confirmed residual but stable degradation in the coupling.

Impact: Provided insights into cascading failures and optimized long-term maintenance strategy. Estimated savings: 6,975 – 7,050 EUR.

Industry: Aerospace

Problem: Severe degradation affected multiple drivetrain components. Without validation, it was unclear whether replacement would resolve the issue.

Solution: Post-replacement monitoring verified that the intervention restored stability, even though minor degradation remained. Finally, process parameters were adjusted to bring production within acceptable quality requirements.

Impact: Confirmed maintenance effectiveness and avoided further reactive downtime. Estimated impact: 25,000–40,000 EUR.

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