Improving Equipment Reliability and Reducing OEM Dependence through CANbus to Contactor Logic Conversion

Industry:
Agricultural and Construction Equipment Manufacturing

About the Customer:
A global leader in agricultural and construction equipment manufacturing, this company has a strong presence in India, with R&D and production facilities in Pune, Noida, and a major manufacturing facility in Pithampur. Known for innovation and quality, the company ranks among the top players in India’s tractor market.

The Backdrop:
At the Pithampur facility, 40 cranes and hoists were deployed across essential areas, including check lines, paint shops, and warehouses. These cranes were equipped with CANbus systems, a complex, message-based communication technology that enables microcontrollers to operate independently without a host computer. Despite being advanced, the CANbus-based cranes had reliability issues that hindered operational productivity.

Due to the system’s complexity, any breakdown required OEM intervention, leading to high costs and prolonged downtimes. Maintenance was challenging as the mean time to repair (MTTR) was extended, impacting equipment efficiency. In contrast, the facility’s Sparkline cranes, which used conventional contactor logic, operated reliably with minimal downtime, highlighting the advantages of a simpler system.

The Challenge:
The Pithampur facility faced several key issues with the CANbus-equipped cranes:

  • High Dependence on OEM Support: Frequent need for OEM assistance led to increased costs and extended downtimes.
  • Lower Equipment Reliability: The CANbus system, while technologically advanced, proved less dependable than conventional systems, affecting equipment uptime.
  • Increased Maintenance Costs: Specialized parts and OEM servicing for the CANbus system were costly, adding to the operational expenses.

Given these challenges, the customer sought a more reliable, cost-effective solution to reduce OEM dependence and streamline maintenance.

The Solution:
To address these issues, Sparkline recommended converting the CANbus system to contactor logic, a simpler, more reliable technology with readily available parts. This change promised to reduce the mean time to repair (MTTR), increase the mean time between failures (MTBF), and significantly cut maintenance costs.

The implementation included:

  1. Pilot Conversion: Sparkline initially converted one crane to contactor logic to demonstrate the reliability and maintenance ease of the new system. The trial showed reduced downtime and faster maintenance.
  2. Full Conversion to Contactor Logic: Following the successful pilot, Sparkline converted all 40 CANbus-based cranes at the Pithampur facility to contactor logic, simplifying maintenance and allowing in-house teams to handle repairs independently.
  3. Enhanced Part Availability: The switch to contactor logic ensured that replacement parts were readily available, further reducing lead times and lowering costs.

This comprehensive solution improved equipment reliability, reduced dependence on OEM support, and provided a cost-effective maintenance option.

A Statement of Overall Benefit:
Sparkline’s conversion from CANbus to contactor logic significantly enhanced the reliability and maintainability of the customer’s cranes. This upgrade not only streamlined operations but also delivered long-term cost savings, allowing the facility to achieve high equipment uptime and substantially reduce OEM dependence.

Benefits:

  • Increased Mean Time Between Failures (MTBF): The simplified system design improved reliability, enabling the cranes to operate for longer periods without failure.
  • Reduced Mean Time to Repair (MTTR): The contactor logic allowed for faster, more efficient maintenance, minimizing downtime and boosting productivity.
  • Lower Dependence on OEM: With the CANbus system replaced, the facility could rely on its in-house team for maintenance, reducing the need for costly OEM support.
  • Improved Ease of Maintenance: The contactor logic system allowed for straightforward maintenance, enhancing overall equipment efficiency and safety.

Sparkline’s tailored solution empowered the customer to improve equipment performance, increase operational efficiency, and achieve substantial cost savings, ensuring reliable and uninterrupted production.