Nanoprecise Saves 8+ Hours of Downtime by Detecting Bearing Failure at a Fortune 500 Automotive Plant

Summary

Nanoprecise helped a Fortune 500 automotive manufacturer prevent unexpected equipment failure and avoid 8 hours of downtime by deploying real-time predictive maintenance on remote machines.

Using a 6-in-1 wireless sensor with vibration and acoustic emission capabilities, the system detected a bearing outer race failure (BPFO) on a remote Table Lift that would have otherwise gone unnoticed.

Early alerts enabled the maintenance team to take corrective action before a breakdown occurred. This improved asset reliability, avoided dangerous manual inspections, and saved thousands in potential production losses.

Automotive predictive maintenance case study - maintenance technician

Customer Profile

One of Asia Pacific’s largest automotive manufacturers, and India’s top passenger car brand, was facing increasing risk from unmonitored critical equipment. As a Fortune 500 company with high-volume production lines, any unplanned downtime could cascade into production bottlenecks, delivery delays, and increased operational costs.

The plant operates complex machinery across remote and high-risk environments, where even brief equipment failure could result in significant productivity losses.

Challenge

A key challenge at the facility was the lack of predictive maintenance on several remote and hard-to-access machines. Due to strict safety protocols and operational constraints, personnel couldn’t inspect equipment while it was running, leading to infrequent checks and reactive maintenance strategies. Without predictive tools, maintenance teams often performed premature manual inspections in dangerous areas, or responded only after equipment had already begun failing. This not only increased labor and safety risks but also amplified the likelihood of unplanned shutdowns.

Solution Deployed

To shift from reactive to proactive maintenance, Nanoprecise deployed its solution, which included MachineDoctor™ sensors, a 6-in-1 wireless sensor capable of delivering real-time health diagnostics across vibration, acoustics, and more.

This solution included:

Real-time Bearing Failure Detection (BFPO)
Acoustic emission monitoring for early-stage fault identification
Remaining Useful Life (RUL) prediction
Automated alerts via cloud dashboard
Remote monitoring of inaccessible machines

By using Nanoprecise, the maintenance team received early-stage fault notifications, which provided enough time to plan inspections, mitigate risks, and prevent costly downtime.

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Assets Monitored

Some, but not all of the assets monitored included:

Table Lifts (in remote locations)
Hydraulic Systems
Electric Motors
Critical Assembly Line Equipment

Observation & Analysis

Fault Modes Identified

Bearing Outer Race Failure (BPFO)
Detected via Vibration Analysis and Acoustic Emission

Condition Trends

Elevated acoustic emission levels
Rising vibration amplitude
Stage 2 Fault Alarm triggered (Looseness)

On Site Findings

Upon inspection, the maintenance team found severe bearing deterioration, confirming early fault detection by the MachineDoctor™ sensors.

Corrective Actions Recommended by Nanoprecise:

Inspect for soft foot and evaluate base/feet alignment
Tighten/strengthen all fixation points and foundations
Check bearing clearance and potential wear
Reassess coupling for alignment and damage
Examine rotating components for cracks or imbalance
Replace bearing during next planned shutdown

Results & Impact

By identifying a bearing failure early on a remote, hard-to-reach Table Lift, the maintenance team acted proactively and safely, along with the following:

8+ Hours of Downtime Prevented
Avoided Emergency Repairs
Improved Team Safety (no risky manual inspections)
Extended Equipment Life

Nanoprecise not only improved asset reliability but also helped the plant reallocate labor more efficiently, enhance safety, and eliminate reactive maintenance!

Conclusion

In high-throughput, high-stakes automotive manufacturing environments, bearing failures and other mechanical faults can bring production to a halt.

Nanoprecise’s acoustic emission sensors, vibration analytics, and Remaining Useful Life estimates enabled this Fortune 500 company to detect a BPFO fault early, prevent unplanned downtime, and optimize maintenance strategy. Through advanced bearing failure analysis and real-time diagnostics, the plant moved toward a more reliable, efficient, and safer operation. Get a demo.