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Roll Former Engineered Monitoring Solution

The Business Case for Implementing AR for Proactive Maintenance

It is imperative that any deployment begin with a business case focused on improving performance, reliability, or operational efficiencies. It is just as important to focus the deployment on how people interact with the information and to ensure users can do so effectively and efficiently. Simply providing more data or data more frequently generally does not yield noticeable improvements to bottom line of a facility. It is recommended that the metrics for success be identified, starting with the basics to get some early wins. This may help garner more attention and support within the facility to expand the deployment and further transform the organization.

Prevent downtime


How much is downtime costing you? Find out how to prevent downtime, save money and prolong the life of your equipment.



Roll Former Machine: A Success Story

As a practical example, this roll forming machine produces guide rail products used in the unit material handling industry. The roll forming machine is critical to the operation of the manufacturing facility, and accounts for a 25% loss of total production when it goes down unexpectedly. It consists of a series of eight gearboxes with upper and lower driven die rollers. The gearing is cantilevered and powered through a worm/spur gear connected in series through a common driveline, powered from a belt-driven air clutch assembly for speed control that is belt-driven from an electric motor.

Many components on machine are unique and have long lead times for replacement. In the past, failures of the gearing, bearing, and belts have gone undetected, forcing operations to halt while replacements are located and installed.

The following business case was developed to determine the financial feasibility of deploying condition monitoring technologies:


Failure Rate/year


50% Daily Down time Cost


Gearbox/unit + Tooling cost/ set + Expedite Fee


2 weeks lost production due to gearbox lead-time


Potential Loss/Year


Annual Cost Savings


Condition Monitoring Investment


Remote Analysis Investment


Return on Investment


Monthly Savings



The condition monitoring system was designed and installed to measure and analyze a variety of machinery health parameters, intended to provide the following:

  • Indication of machine degradation weeks in advance of failure
  • Data visualization and conceptualization for maintenance management personnel unfamiliar with vibration waveform and spectral analysis
  • Wireless connectivity of the monitoring systems to the server, eliminating the need to run local networking cable to the metal forming machine
  • Automated email and SMS text alerts for changing or abnormal conditions




The data acquisition hardware was installed near the equipment, minimizing cable and conduit runs. The hardware was connected to server-based software installed in the cloud that provides tools for configuration, alert/alarm protocols, trending and analysis.Once the data is secured in the server, it becomes simple to generate an AR experience.

Using these technologies, the facility is now better equipped to proactively maintain this roll forming machine, eliminating the need for time-based strategies. A team of subject matter experts now have simple and quick remote access, allowing them to resolve issues and perform diagnostics without incurring any travel expenses. This access has also allowed a higher rate of first-time fixes.

Since implementation of the condition monitoring system, there has been zero unplanned downtime. Perceptiv™ Intelligence is empowering facilities to more proactively manage their assets and reduce unnecessary expenses associated with equipment degradation, unplanned failures, and ineffective maintenance strategies.




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