Case studies
Manufacturing: Automotive, Plastics & Rubber case studies
Monitor compressed air, electrical demand and equipment condition—including the older assets your existing systems may not cover.
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 factories like these.
WaterManufacturing: Automotive, Plastics & Rubber
Chiller circuit leak isolated without a shutdown
An automotive factory
Continuous monitoring helped identify and isolate a leaking cooling loop while the production line remained in operation.
1 loopisolated
Compressed airManufacturing: Automotive, Plastics & RubberMetal Fabrication & Finishing
Compressed air leaks in a stamping operation
A Tier 2 automotive stamping factory
Permanent monitoring revealed compressed air continuing to flow into an otherwise idle building overnight.
20–30%of compressor output
Predictive maintenanceBulk Handling & Rail LogisticsManufacturing: Automotive, Plastics & Rubber
Conveyor-drive bearing degradation detected six weeks before failure
A bulk handling facility
The bearing’s vibration signature began changing approximately six weeks before the projected failure point.
6 weeksof warning
Cooling towersWaterManufacturing: Automotive, Plastics & RubberBuilding Materials, Concrete & Aggregates
Cooling tower blowdown optimization
A plastics manufacturing factory
Blowdown was controlled by a timer rather than conductivity, causing usable water to be discharged unnecessarily.
1 setpointchanged
Natural gasBuilding Materials, Concrete & AggregatesManufacturing: Automotive, Plastics & Rubber
A 1970s boiler brought onto the dashboard
A heavy manufacturing factory
A fifty-year-old boiler, integrated through its 4-20 mA output. Nothing was ripped out.
4-20 mAintegration
Energy & electricityManufacturing: Automotive, Plastics & Rubber
Three factories, one unit of production, one outlier
A manufacturer with three factories
Same product, same equipment, and one factory used about 40% more energy per unit.
~40%more energy per unit
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
See what these numbers look like in your factory.
Bring us a shift and a stack of bills. We will walk the floor with your team, point at what is worth metering first, and put a figure beside it.
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