Introduction
Staying ahead in the competitive global manufacturing landscape requires leveraging the latest technology to enhance efficiency, safety, and reliability . RYAM, a true industry leader, exemplified this by proactively integrating KCF Technologies’ Comprehensive Machine Health Platform solutions into their operations—resulting in remarkable improvements.
The journey began in early 2021 with a pilot project at one facility, deploying a few hundred sensors to monitor critical equipment. The success of this pilot prompted RYAM to expand KCF sensors across all their sites, with the Jessup facility now boasting approximately 2,600 sensors covering about 95% of its critical machinery.
2,600 sensors covering about 95% of its critical machinery.
The Evolution of RYAM
This extensive sensor coverage provides consistent safety, supports world-class environmental standards, and optimized processes. Transitioning from monthly equipment checks to continuous, real-time monitoring with KCF’s technology allows RYAM to detect and address issues before they become asset failures. This significant shift has reduced unplanned downtime and enhanced overall machine reliability, with data now being collected every five to ten minutes instead of once a month.
With the actionable insights provided by continuous monitoring, technicians can preemptively address potential failures. For example, monthly vibration checks often missed early signs of bearing defects in their pull-washer systems. Continuous monitoring with a comprehensive machine health platform now catches issues early, preventing costly breakdowns and ensuring smoother operations. Taking a proactive approach with continuous, real-time monitoring also improves the work-life balance for employees by reducing emergency repairs outside of regularly scheduled work hours.
The switch from preventive and route-based maintenance to predictive maintenance fosters a culture of data-driven decision-making at RYAM. Real-time data and insights have become integral to the troubleshooting process, allowing the maintenance team to optimize schedules and prioritize assets needing attention the most. In addition to significant reductions in downtime, real-time data has led to improvements in equipment lifespan and performance, particularly among rotating pumps and fluid handling systems.
By embracing advanced sensing technology and real-time data analytics, RYAM has not only improved operational efficiency and reduced downtime but also created a safer, more predictable workplace. This transformation is a testament to the power of cutting-edge technology partnered with shop-floor engagement to drive industrial innovation and operational excellence.
The partnership between RYAM and KCF Technologies has been transformative. Providing RYAM with the tools and insights needed to not just keep up but stay ahead in a competitive industry.
Optimize Your Machine Health
Reduce unplanned downtime by getting to the root cause of machine failures. Learn how KCF’s machine health optimization platform will help you achieve peak plant performance. Download the KCF Guide to learn more about optimizing your machine health.
