Proactive Asset Maintenance: A Worthington Steel Case Study

In the fast-paced industrial maintenance world, staying ahead of equipment failures and having proactive asset maintenance is critical. Worthington Steel, a leader in steel processing, has made significant strides in this area by leveraging Motion Amplification® technology. Here’s an in-depth look at their journey, successes, and insights.

Embracing New Technologies

At Worthington Steel, Jeremie Lieb focuses on transformation with the skilled trades groups and focuses on asset management and reliability. With 27 years at the company, Lieb is a transformation lead who shared the company’s vision for finding a reliability partner to develop their skilled labor groups into proactive resources.

“Reactivity within our maintenance groups is never a good thing. I focus on safety factors as number one, then we aim to slow things down, ensure good work plans, and use technologies like Motion Amplification to be proactive,” says Lieb.

Building a Proactive Culture

The journey began with training and equipping maintenance teams with Motion Amplification tools. The main tool utilized is the Iris M™ Traveler. This system allows their groups to start building a baseline and developing processes that did not exist. This technology allows their technicians to visualize previously invisible issues, such as pipe strain and bearing failures.

Case Study Highlights

1. Acid Pump Issues:

   • Problem: Annual pump replacements due to undetected pipe strain.
   • Solution: Motion Amplification revealed significant pipe strain and misalignment, which was not picked up due to the low frequency.
   • Outcome: Addressing the root cause reduced pump failures, saving significant downtime and annual repair costs.

1. Tension Leveler Roll Issues:

   • Problem: Brand new install of tension leveler roll immediately started showing bearing wear and bearing failure.
   • Solution: Motion Amplification revealed significant directional movement at the base, which showed the base did not correctly support the asset.
   • Outcome: The team rebuilt the motor quickly, preventing the entire line from being taken down. The timely rebuild averted potential failures and ensured operational safety and efficiency.

“The big story is that we saved a lot of money on this one. Utilizing the Iris M Traveler, we quickly got ahead of the Tension Leveler Roll issue before it took down the entire line and caused significant downtime. A great win for us,” Jeremie Lieb says.

Training and Implementation

Training is a cornerstone of Worthington’s strategy. Technicians receive training on-site and at RDI facilities, enhancing their skills and confidence in using the technology. Worthington Steel expresses how crucial it was for their team to fully understand and utilize the technology. They said other team members came forward requesting training.

Return on Investment

Jeremie Lieb stated that the technology’s cost was recovered in under six months due to savings from failure prevention and reduced downtime. One notable success was a multi-million dollar savings from resolving a major issue on their pickle line.

“The rewards you’re seeking are in the work you’re not doing, and now that we’re doing the work, we’re seeing those rewards. Proactive maintenance through Motion Amplification has proven invaluable,” Lieb emphasizes.

Future Outlook

Worthington Industries plans to expand Motion Amplification across all facilities, ensuring every plant can benefit from this transformative technology. The focus is on continuous improvement and leveraging technology for better maintenance strategies.

“We aim to integrate this technology into our standard work for new installations and maintenance checks, ensuring long-term reliability and safety,” says Lieb.

Worthington Industries’ proactive approach to maintenance, powered by Motion Amplification, showcases the profound impact of adopting new technologies in industrial settings. By focusing on training, implementation, and continuous improvement, they have set a benchmark in reliability and operational efficiency.

This case study underscores the importance of being proactive, leveraging cutting-edge technology, and continuously training teams to stay ahead in the ever-evolving industrial landscape.

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