Reliability and condition
monitoring solutions
for the automotive
manufacturing industry

Why partner with Bently Nevada?
We have earned your trust. For six
decades the Bently Nevada product line
has supported the most demanding
applications in multiple industries. Andeven as we protect and monitor yourmachinery, we constantly strive to refine
and improve our offerings—and help
enable your success.
We design and deliver solutions for allof your monitoring needs—including
sensors, distributed and rack-based
monitors, software, and supporting
services—with the following goals:• Increased availability and production• Lowered maintenance costs• Reduced risk in terms of safety,environmental, and asset upsets
Quantifiable, proven results:• Over 60 years of innovation in asset
protection and condition monitoring• Over 85,000 3500 Series monitoring
systems installed globally• Over 4 million sensor
monitoring points• Services support globally• Over 1,600 System 1 software
users worldwide• More than 240 international patents
issued, including over 150 in the U.S.
• More than 360 international patents
pending, including over 95 in the U.S.

Industry challenges

Condition monitoring
While condition monitoring may not be the only element in a
successful reliability program, it is nonetheless an essentialelement. For years, we’ve been taught that the older anasset is, the more likely it will fail. As such, many plants have
evolved elaborate and finely tuned maintenance schedules
based on calendar intervals or running hours.
There’s just one problem with that approach: time- or
usage-based maintenance strategies alone are only valid
for 10 to 15% of the assets in a typical industrial facility.
In other words, if you have applied a time or usage
based only maintenance strategy to the majority of yourequipment, most are getting “maintained” when they don’t
need to be. That’s wasteful, and it’s one of the major reasonsthat many companies are overspending on maintenance.
In other cases, the asset may fail before it reaches
its scheduled maintenance interval. Frustrated, plantmaintenance staffs are left to wonder “what went wrong.”

Today, many of our world’s automotive plants are operating 24/7 to meet the global demand. Automotive manufacturing’s‘always-on’ schedule, together with a high level of automation, greatly increases the vulnerability of substantial losses
if just one machine goes offline. This exposure is prevalent since many automotive plants still rely on a rearview mirror
maintenance strategy, such as tracking machine hours for scheduled maintenance or even using a “run to break” approach.
Consequently, an automotive plants production operation’s reliance upon its machinery has never been more important.
Downtime is more expensive. Uptime is more valuable. Operators need to know if they can push machinery to its designcapacity and beyond while remaining safe and maximizing the balance between useful life and capacity. And, as always,operators need to remain safe—for their families, for their communities, and for the environment.

Unreliable assets have enormous consequences. What if
your assets could consistently operate at or above theirrated capacities, for a greater percentage of total hours eachyear, all while spending less money on maintenance? That’s
exactly what today’s best companies have discovered how
to do. Industry studies show that the average facility spendsapproximately 5% of its Replacement Asset Value (RAV) onmaintenance each year. In comparison, best performers
spend 60% less—just 2% of RAV—while enjoying better uptime,efficiency, and profitability. It’s not about simply spending
less on maintenance, it’s about working differently—
working smarter—to achieve more reliable automotive
manufacturing operations.

Benefits with Bently Nevada
Closing the gap between your reliability “goals” and what
you are actually obtaining from your efforts typically involves
the following three categories:•	
Processes: Our comprehensive services help customers
assess their goals, identify the reliability gaps in theircurrent operations, and then implement the appropriate
corrective actions.
•	
Tools: Our Bently Nevada product line is world-renowned
for unsurpassed quality in rotating machinery condition

monitoring. Everything needed to address the assets in
automotive plants and other metal production facilities
are available, from sensors to continuous monitoring
systems to portable data collectors and analyzers.
And, it’s all brought together in a unified platform for
asset condition monitoring and diagnostics—Bently
Nevada’s System 1* software. We also assist customers
in integrating and using their already installed tools, suchas computerized maintenance management systems(CMMS) and reliability software.
•	
People: Reliability is about more than just technologies
and processes. Armed with even the most sophisticatedtools and effective strategies, companies can fail to reach
their reliability goals unless they are able to successfullychange the way they work. Reliability is a company-wide
effort that touches operations, maintenance, planning andscheduling, purchasing, management, and engineering.
Bently Nevada is able to help customers change the way
they work by addressing the organizational culture issues
that keep companies mired in ineffective processes,
helping them transform their businesses and balance
sheets.
Because Bently Nevada is able to fully address each one ofthese, we are able to solve the whole problem—not just bitsand pieces.

Process DataAnalysis

HigherConsequence of failure

Reliability: the key to a successful future

Lower

High Critical

CriticalMedium toLow Critical

Portables

Different assets, different approaches
Not all assets are created equal. In the automotive industry;
ventilation fans, robots, chillers, cooling tower fans, conveyors
and cranes are highly critical to operations. Other assets
are less critical. And still others have little impact on safety,environment or production, with only maintenance costs as
the primary consideration. As such, a variety of condition
monitoring products and approaches are required.
Today we understand that the probability of an asset failure
is often highest just after it has been placed in service (orundergone maintenance). Following this “infant mortality”
period, its probability of failure becomes constant and does
not rise linearly over time. This means that running hours
and calendars are poor “predictors” of failure. How do you
know when such assets will fail if the time-based intervals
can’t be trusted? By measuring the mechanical condition of
the asset – vibration, temperature, efficiency, oil chemistry/particulates, and other physical parameters. In other words,
condition monitoring.
This approach results in maintenance only when thecondition indicates the asset is failing. Further, failure
progression can often be trended quite accurately,
allowing maintenance intervention at exactly the righttime—not too soon, not too late. And, condition data canbe remarkably precise, indicating not just that the asset isfailing, but exactly what is wrong, providing vital input to aroot cause investigation that can help to prevent a similar
failure in the future.

Wireless,scanningOn line,continuous CM
or Protection

On linecontinuous CM
and Protection

Bently Nevada service menu
Key benefits
Get it right the 1st time

Implementationservices• Ensure your assets are protected andmonitored when you’re ready to startup• Avoid costly delays and rework• One source to design, plan, manage,and execute the installation• Avoid startup trips due to improper
installation and configuration

Keep your system healthy and optimized

Proactivesupport• Prevent instrumentation related false trips• Prevent and minimize potential data loss events• Keep up to date and compliant with the best
technologies available• Access the expert support you need when you
need it mostActionable insights you can trust

Asset healthand consulting• Understand your asset health to optimize
outage and maintenance planning• Plug in to our global network of machinery
experts with remote monitoring• Professional OEM agnostic machinery
diagnostics when and where you need it• Custom analytic development and tuning
to pinpoint specific conditions
Stay ahead of evolving cyber threats

Cybersecurity1

Training
and education• Ensure your system is up to date and protected
as threats continually evolve• Identify and mitigate cybersecurity risks
to your operation• Keep your system both secure and accessible
with advanced security technologies andarchitectures leveraging data diodes anddatabase replication
Critical skills that amplify yourmachinery management capabilities• Enable your personnel to operate and maintainyour monitoring and protection system• Enable your operation to maximize the valueof your system leveraging expert product andapplication training and knowledge

Up to$1M/day

100%

Avoided costfrom lost
production,
secondaryprocess &equipment
damageService work
guarantee
1 year warranty
standard on
all service work

80%

Industry widemachineryalarms & eventsare due toinstrumentation>90%

Typical reduction
in non-actionable
alarms & events

100% ROIA single machinesave often resultsin completemonitoring
contract
payback andmore5-10X

Cost reduction
for well planned
maintenanceoutage vsunplanned reactive
outage29%

Patchmanagement
can reduce
your attack
surface up
to 29%

243 days

Average time
before detectionthat a system iscompromised

400+

Customer courses delivered each yearin 10 languages and over 45 global
locations1. https://www.us-cert.gov/sites/default/files/documents/Seven%20Steps%20to%20Effectively%20Defend%20Industrial%20Control%20Systems_S508C.pdf

You canrely on us
For more than 50 years, we’ve been
supplying condition monitoring
solutions to machinery-intensiveindustries. We also bring two decadesof experience conducting reliability
improvement projects. Customers
turn to us for a simple reason: lastingvalue. Our solutions demonstrate
their worth, day in and day out. We
combine the highest quality products
and responsive customer support witha service team that takes the time tounderstand the uniqueness of yourplant, your personnel, and your goals.
Our products can be found in manyof the world’s automotive plants.
Today, many of those same plants
are turning to Bently Nevada for amore comprehensive solution to theirneeds, moving beyond just machinery
protection instrumentation on a few
assets to plant-wide strategies andsystems for improved environmental
compliance, safety, asset production,
quality and reduced operation andmaintenance costs.

Opportunities forcondition monitoring in
automotive plants
Highly automated, high-yield automotive plants are ideal
candidates for condition monitoring systems. Remotely
monitoring the health of equipment throughout theproduction process helps plant managers make informed,
real-time maintenance decisions which ultimately reduce
unforeseen downtime, promote safe work environments, andmaximize profits.

System 1 – one platform, endless possibilities
Body shop

Welding machines
Conveyors
Robots/robotic arms

Improve equipment reliability, uptime and efficiency

Paint shop

Extraction fans
Humidity controllers
RobotsWater circ pumps
LathesBlowers
Conveyors

System 1 represents Bently Nevada’s flagship condition
monitoring solution that seamlessly integrates with our industry
leading products including online and portable devices.
System 1 provides scalability by adapting to the condition
monitoring requirements at your facility, as well as flexibility byconnecting to any Bently Nevada’s field devices.

Assembly shop

Conveyors
Robots/robotic arms

Press shopPumps
Press drive motors

Infrastructure

Power generation
Cooling systems (chillers)
Cooling towers

Powertrain

Drilling machines
MotorsSpindlesCnc
Hydraulic pumps
Extractors

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BHCS34129 (04/2020)

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