Case studies
Manufacturing — automotive, plastics & rubber case studies
Compressed air, electrical demand and equipment health on plant floors where the oldest asset is often the most important one.
7 of our 19 case studies are in this sector.
All 19 case studies What we meter in Manufacturing — automotive, plastics & rubber
A real page with its own address (§B.2), reachable from the Industries hub, the sector page and the library’s industry rail.
What we found in plants like these.
WaterManufacturing — automotive, plastics & rubber
Chiller circuit leak isolated without a shutdown
An automotive plant
A leaking cooling loop found and isolated with the line still running.
1 loopisolated
Illustrative scenario
Compressed airManufacturing — automotive, plastics & rubberMetal Fabrication & Finishing
Compressed air leaks in a stamping operation
A Tier 2 automotive stamping plant
The most expensive utility per unit of work, leaking into an empty building overnight.
20–30%of compressor output
Illustrative scenario
Predictive maintenanceBulk Handling & Rail LogisticsManufacturing — automotive, plastics & rubber
Conveyor drive bearing degradation caught six weeks early
A bulk handling facility
A bearing changed its signature about six weeks before it would have seized.
6 weeksof warning
Illustrative scenario
Cooling towersWaterManufacturing — automotive, plastics & rubberBuilding Materials & Heavy Industry
Cooling tower blowdown optimization
A plastics manufacturing plant
Blowdown running on a timer instead of on conductivity, discharging good water.
1 setpointchanged
Illustrative scenario
Natural gasBuilding Materials & Heavy IndustryManufacturing — automotive, plastics & rubber
A 1970s boiler brought onto the dashboard
A heavy manufacturing plant
A fifty-year-old boiler, integrated through its 4-20 mA output. Nothing was ripped out.
4-20 mAintegration
Illustrative scenario
Energy & electricityManufacturing — automotive, plastics & rubber
Three plants, one unit of production, one outlier
A three-plant manufacturer
Same product, same equipment — one plant used about 40% more energy per unit.
~40%more energy per unit
Illustrative scenario
Temperature & humidityMetal Fabrication & FinishingManufacturing — automotive, plastics & rubber
Welding bay CO and CO₂ monitoring
A metal fabrication shop
Air quality in the welding bay, watched continuously instead of checked quarterly.
Continuousvs. quarterly
Illustrative scenario
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