Bently Nevada Slashes PLC Maintenance Costs by 40% with Vibration Monitoring

Bently Nevada Slashes PLC Maintenance Costs by 40% with Vibration Monitoring

Proven Results in Industrial Automation

A manufacturing plant reduced annual PLC motor maintenance costs from $50,000 to $30,000 by implementing Bently Nevada’s System 1 across 20 critical motors.

Unplanned downtime decreased by 15% within 6 months, while motor lifespan extended by 2.5 years on average.

Over 85% of clients reported a 30% drop in failure rates after 12 months of deployment.

Precision Monitoring Technology

• Accelerometers capture vibration data at 10,000 samples per second, detecting anomalies as small as 0.002 g.
• Proximity probes measure shaft displacement with ±0.05 mm accuracy, preventing misalignment issues.
• System 1 software analyzes 50+ parameters in real time, including temperature and frequency spectra.

Financial and Operational Impact

25% reduction in spare parts inventory costs by replacing reactive maintenance with condition-based scheduling.

18% boost in production efficiency across 15 facilities, saving 500+ hours annually in downtime.

70% of potential motor failures were predicted and prevented using AI algorithms with 98% diagnostic accuracy.

ROI and Scalability

Businesses achieve full ROI within 8–14 months, with solutions scalable for:

• Small plants (10–50 motors): Save $15,000–$50,000/year in maintenance.
• Large facilities (200+ motors): Cut costs by $200,000+ annually.

Bently Nevada’s systems monitor 1,000+ assets per site, processing 5 TB of data monthly.

Global Support and Expertise

Backed by 50+ years of industrial experience, Bently Nevada provides:

• 24/7 remote monitoring with 2-hour emergency response.
• Customizable dashboards highlighting top 10% high-risk assets.
• 95% customer satisfaction rate across 1,200+ installations worldwide.