How Buzzi Unicem USA Overcame Conveyor Roller Failures
From Breakdowns to Breakthroughs:
Buzzi Unicem USA Case Study
Buzzi Unicem USA, a leading cement manufacturing company in the US, is headquartered in Bethlehem, PA. The company is nationally recognized for its dedication to maintaining and enhancing the occupational health and safety of its employees, contractors, and suppliers across all seven cement plants and 34 cement terminals. They aim to eliminate injuries and occupational illnesses from the workforce.
The Challenge: Conveyor Roller Failures
At the Maryneal, Texas plant, Buzzi Unicem USA faced an ongoing battle with frequent conveyor roller failures. Each failure threatened the plant’s safety and disrupted the operational flow, causing significant production delays. The challenge was compounded by the need for extensive and often hazardous repair operations, which posed further risks to the maintenance team. The facility needed a more reliable and cost-effective solution for these persistent issues.
The Search for a Solution: Iris CM™
Buzzi Unicem USA started researching to find a solution to address the immediate problem and prevent future occurrences. After evaluating several options, they implemented RDI Technologies’ Iris Continuous Monitoring (Iris CM™) system. The driving factor for this decision is a need for a system that could provide continuous, real-time monitoring without disrupting ongoing operations.
Seamless Integration: The Installation
In March 2024, during a scheduled plant downtime, Buzzi Unicem USA installed the Iris CM™ system. This careful timing ensured smooth installation that did not interfere with the plant’s operations. The integration was further enhanced by RDI Services, which provided weekly remote data analysis. This service equipped the Buzzi maintenance team with actionable insights, enabling them to perform preemptive maintenance and address potential issues before they escalated.
Immediate Impact: Early Detection and Quick Resolution
The impact of the Iris CM™ system was almost immediate. Within just a week of installation, the system identified a missing roller. This early detection allowed the maintenance team to quickly address the issue during a scheduled maintenance window, avoiding unscheduled downtimes. The ability to detect problems early and schedule repairs at convenient times proved to be a game-changer for Buzzi Unicem USA.
The Results: Transforming Operations
The introduction of the Iris CM™ system brought about significant improvements in several key areas:
Operational Efficiency
With the ability to detect and address issues promptly, Buzzi Unicem USA avoided potential downtimes, ensuring continuous production. The seamless flow of operations meant that the plant could maintain high productivity levels without the constant fear of unexpected breakdowns.
Cost Savings
The cost savings achieved through the early detection of issues and the non-invasive nature of the Iris CM™ system were substantial. Traditional repair methods often required lengthy shutdowns and extensive labor, but the Iris CM™ helped significantly reduce those costs. The system’s efficiency translated directly into financial savings for the plant.
Enhanced Plant Safety
Safety was one of the most critical improvements the Iris CM™ system brought. The system minimized the risks associated with these activities by reducing the need for manual inspections and extensive repairs. The comprehensive monitoring capabilities of Iris CM™ provided the maintenance team with a safer, more efficient way to manage the plant’s operations.
A New Era for Buzzi Unicem USA
The success of the Iris CM™ system at the Maryneal plant marked the beginning of a new era for Buzzi Unicem USA. The plant overcame conveyor roller failures and set a new standard for operational efficiency, cost savings, and safety. This case study serves as a testament to the power of innovative technology in transforming industrial operations and achieving long-term success.
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