The Situation
A large facility processing potatoes had contacted their local HAYLEY DEXIS team reporting a breakdown to a critical gearbox on a main production line. After sending photographs to HAYLEY DEXIS, and with the assistance of the specialists within the HAYLEY DEXIS | Drives, the unit was identified as a Hub City 1:1 ratio gearbox manufactured in the USA. The cost of a replacement unit was only £952, but it was only available with a twenty-four week lead time.
The Solution
With the lead time on a like-for-like replacement unacceptable for the customer, HAYLEY DEXIS opted to explore the option to repair the asset. The failed gearbox was collected and sent to the HAYLEY 247 DEXIS engineering centre in Dudley where it was stripped and inspected. A report of the findings was submitted
back to the customer before work commenced on a full refurbishment. Special American bearings and seals were used, with shafts and housings reverse engineered on-site at HAYLEY 247 DEXIS. The work was completed and the refurbished unit was back with the customer within just six days.
"THIS SAVED THE CUSTOMER A TOTAL OF 138 DAYS WORTH OF DOWNTIME LOSSES"
The Result
With the gearbox being refurbished, rather than replaced for new, the production line was restored to full capacity within six days, rather than twenty-four weeks. This saved the customer a huge one-hundred-and-thirty-eight days worth of downtime losses. This was valued at £103,500, a cost signed-off by the customer.