WEBEE USE CASE

ROTATING MACHINES
Machine health monitoring
for supporting equipment

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ROTATING MACHINES
MACHINE HEALTH
INDUSTRIES SERVED

CONSUMER PACKAGED GOODS

PERSONAL CARE
AGRITECH
FOOD & BEVERAGES
INDUSTRIAL AGRICULTURE
MINING O I L & G A S
E N E R G Y PHARMA
MACHINE APPLICATIONS

Electric Oil and Vacuum Ventilation

Engines Pumps Systems

Compressors Seed Conveyor Belts

Elevators

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THE CHALLENGE
INTRODUCTION
Supporting equipment makes up more obtain real-time information about
than 60% of an average manufacturer's machine behavior. This attempt failed
rotating assets. And in many cases, these and resulted in high costs that couldn't
are legacy machinery. This client was in clearly demonstrate ROI. Despite the
need of a better understanding of the failure, the client needed to find an
behavior of critical assets as well as alternative way to understand
legacy auxiliary machines. To address conditions in real time and monitor
issues faced within their existing machine behavior to ultimately predict
systems, the client attempted to breakdowns in a more agile and efficient
implement wired systems technology to way.

"MONTHLY MANUAL CHECK-UPS ARE COSTLY AND INEFFICIENT.

WE CAN ONLY GET 75% OEE OUT OF OUR EQUIPMENT"
CPG CLIENT PLANT MANAGER

THE PROBLEM: PREVENTIVE MAINTENANCE

ROTATING MACHINES
Rotating machines are at the heart of Preventative maintenance is the
the manufacturing process. More often cornerstone of optimizing ROI in critical
than not, these are legacy machines, assets such as manufacturing
meaning operations may be more machinery. Thus far, the typical
challenging than their modern preventive maintenance schedule of
counterparts. Even in digitized plants, rotating machines involves monthly
SCADA systems have no way of (and in some cases even weekly) manual
providing relevant information about check-ups, monitoring engine
rotating machines that allows them to temperature, machine vibration, and
monitor real-time conditions in an energy consumption. These types of
effective way. Monitoring key metrics, preventative maintenance schedules are
such as vibration levels or energy costly solutions that can often total
consumption enables optimized $48,000 USD a year, and typically only
functionality and efficiency of guarantees 75% Overall Equipment
machinery. Without this information, Effectiveness (OEE) ratings.
maintenance becomes reactive rather While this is the common approach to
than preventive, and can have a preventative maintenance in rotating
significant impact on operations and machines, many things can awry in a
resources. month.

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Without any type of warning system, a In order for broken equipment to be

machine can be experiencing a whole repaired or replaced, production lines
host of issues, one often leading to have to be stopped, leading to a loss of
another. For example, a machine could productivity. In addition, restarting
overheat, experience over-vibration, production lines may involve additional
have an abnormal engine start or a spike work performed on other machines that
in energy consumption without anyone have been affected by the stoppage.
knowing. These issues can quickly come out of
control having a serious impact on a
These situations inevitably lead to business’s operations.
machine downtime, which, depending
on the industry and scale, can result in
daily losses between $120,000 USD to
well over $2 million USD.

THE SOLUTION
When Webee designed solutions for this client’s problem, there were two main goals:

1. Provide the client with the real-time information they need

2. Keep costs reasonable, ensuring adequate ROI was provided

By offering tasks management and prescriptive maintenance through AI algorithms

that discover and understand anomalies, the client received the most effective
composition of solutions possible.

OUR APPROACH

Within hours, a comprehensive set of These types of sensors are wireless and
solutions were installed, with a special optimized to last up to 5 years, with low
focus on the measurement of key battery consumption. They are “stick and
variables in real-time with a non- play”, meaning they are attached to and
intrusive approach. LoRaWAN sensors paired with the machine, immediately
were used, allowing for the accurate sensing, and sending information to a
measurement of vibration, temperature, LoRaWAN gateway in real-time.
and energy consumption.

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OUR APPROACH (CONT.)

With a no-code approach, Webee’s make smarter, more informed decisions,

software collects the data gathered by setting thresholds and alerts that can be
the sensors and normalizes it in real- shared via e-mail and SMS. Users can set
time. The benefit to this is that the user and receive notifications when a variable
doesn’t need any specialized changes, create multiple dashboards and
programming skills to collect the data. reports, and use AI to recognize patterns
Only a few clicks are needed to pair the and detect anomalies in a machine’s
sensor in Webee’s platform, linking it to operation. They can also access historical
the corresponding asset, ensuring data reporting and recommendations
visualization is up and running. From through AI anomaly detection. This
there on, the platform processes the data feature helps users predict when a motor
in real-time, allowing users to easily could be ready for a maintenance task,
customize the solution. enabling them to be proactive rather
Using customizable features, clients can than reactive.

LoRaWAN DEVICES INSTALLED

Energy Consumption Sensors – These sensors are Temperature and Vibration Monitoring Sensor –
unobtrusive, clamp-on and feature a range of up Mounted to the surface of dryers as well as low
to 10km depending on the environment. The and high-pressure compressors, these dual-
measurement range spans 100mA up to 75A. sensors measures acceleration in the X, Y, and Z
Higher and lower range sensors are also available, axes in meters per second. In addition, they
as well as single-phase and three-phase variants. measure surface temperature ranging from -20ºC
to +55ºC. Depending on the environment, the
transmission range for these sensors can reach up
to 10km.

LoRaWAN Gateway – The range of a LoRaWAN Additional Sensors – Sensors for measuring
gateway can exceed 5km in urban environments other variables, as well as other ranges of the
and 15km in extra-urban environments. They are same variables, can be added at the client’s
IP67 compliant, meaning they can be installed request. Other sensor outputs such as those
outdoors, and can be connected to the network from Modbus/RS485 protocol devices can be
via Ethernet where available. Alternatively, it can sent to the platform via a LoRaWAN
also connect to 3G and 4G/LTE networks using a transceiver.
SIM card.

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DASHBOARDS
Machine Condition Monitoring – Enables real-time and historical vibration (3-axis acceleration
and velocity), surface temperature, and energy consumption. Access to variables not supported
by current SCADA is obtained using non-intrusive battery-powered sensors.

REAL-TIME

HISTORICAL DATA - MAXIMUM VALUES

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DASHBOARDS (CONT.)

HISTORICAL DATA - TRENDS

Operational Efficiency – Prevent machine downtime and optimize downtime through

automated prescriptive maintenance and tasks management.

User-managed real-time alerts can be set in relation to any of the aforementioned

variables and can be turned on and off with the flick of a switch.

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THE RESULTS
OUTCOMES

Improved access to both historical and real-time machine health data

Prevention of unexpected downtime
Reduction of scheduled line downtime
Focus shifted from preventive to predictive maintenance approach
Increased ROI and reduced costs

IMPROVED EFFICIENCY RATINGS ­– FEATURING A REMARKABLE

INCREASE FROM THE INITIAL 75% TO 87% OEE. THIS MEANT FEWER
DOWNTIME-RELATED LOSSES AND DECREASED MANUAL
MAINTENANCE COSTS.

Real-Time Monitoring – Vital

measurement of key metrics, such as
engine surface temperature, 3-axis
acceleration, and velocity to measure
vibration and power consumption.

SMS and e-Mail Notification Capability –

Notifications are sent out when alert
parameters are met or exceeded. For
example, a notification is sent out when
the engine surface temperature meets
the given threshold.

Control Panels for Historical Machine

Data – Allows for anomaly detection,
such as abnormal machine start spikes,
axis imbalance, excessive vibration, and
phase imbalance. This provides the
ability to see when and how a threshold,
such as higher surface temperature than
normal, was met or exceeded via
simplified reporting using line charts.
Maximum/minimum historical values
and averages are also easy to visualize.

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USE CASE
FAST-FACTS
UP TO

16% 2M
INCREASE IN OEE IN LOSSES AVOIDED
PER DAY

+90% $45k
OEE GUARANTEED SAVED ANNUALY IN
MANTENANCE TASKS
PER MACHINE

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WHAT'S NEXT
Once connected, devices begin gathering and storing historical data and sending
alerts when thresholds are met. The next step involves categorizing those alerts and
letting the platform know what failed and how it was solved. With enough data
inputs and through machine learning, AI-enabled prescriptive maintenance can not
only inform users when maintenance is needed. In addition, this also lets users know
what the most likely reason for maintenance may be, and the appropriate solution to
address the issue. This is particularly valuable in remote, hazardous, or difficult to
access locations, where logistics are costly and worker safety is paramount.

WHY WEBEE?
We have succesfully deployed machine monitoring solutions in varying industries
and solved the intricacies of their specific applications. Our operational know-how
enables us to understand the needs of every stakeholder and our technical team has
worked side-by-side with them to understand when and how they need to have
access to insights and how best to leverage them in making informed decisions.
Take a look at the key features that make Webee a perfect fit.

WIRELESS SENSORS - NO INSTALLATION NEEDED

EXPERT INSTALLATION SUPPORT WITH NO DOWNTIME

USER-MANAGEABLE ALERTS VIA EMAIL AND SMS

PRESCRIPTIVE MAINTENANCE

SIMPLE DASHBOARDS - VIEWS FOR MULTIPLE USERS

CLOUD-BASED WITH FREE UPGRADES

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REACH OUT
TO US
We are eager to take on the challenges of Industry 4.0
and bring on the next level of digital transformation to
your business. Feel free to reach out to schedule a
meeting. Ready to take the next step? You can also book
a demo.

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