Predictive insights reduce downtime for window patching machine manufacturer

The Challenge

A leading European OEM specializing in window patching machines struggled with production disruptions caused by misalignments in their mechanical cutting mechanisms. Precision blade alignment on the rotating cylinders directly impacted cut quality, with any deviation quickly resulting in substandard products and machine downtime. When issues occurred, the traditional resolution required dispatching factory service technicians for on-site alignment or replacement—extending downtime periods and increasing operational costs for both the manufacturer and their customers.

The Solution

To address these challenges, ei³ implemented Symphony—a specialized sensor system that captures frequencies beyond human hearing capabilities. Unlike manual inspections, Symphony provides continuous monitoring of the machines, constantly analyzing operational sounds for anomalies.

By positioning sensors near the cutting blades, Symphony detects subtle changes in cutting action well before they affect product quality. This data feeds into advanced AI-based machine learning algorithms developed by ei³'s data science team, which identify patterns indicating potential future failures.

The system generates early alerts when it detects degradation patterns, enabling maintenance teams to schedule interventions before critical failures occur—transforming reactive maintenance into planned preventive action.

Results

• 70% Reduction in Unplanned Downtime: Implementation of the Symphony solution successfully prevented machine downtimes that would have occurred without early detection.

• Significant Cost Savings: By minimizing emergency service visits and unscheduled production interruptions, the solution delivered substantial cost savings through reduced maintenance expenses and preservation of production capacity.

• Increased Operational Efficiency: Maintenance could be scheduled during planned downtime periods, maximizing productive hours and ensuring consistent product quality throughout equipment operation.
  
  
  

About The Machine Maker

This company stands as a premier manufacturer of high-quality tray forming and rotary window patching machines with centralized development, design, and production facilities in Germany and active operations across 62 countries globally. In just three decades, they have established themselves as market leaders through their dedication to advancing next-generation packaging solutions.