Case studies
Manufacturing: automotive, plastics & rubber case studies
Compressed air, electrical demand and equipment health on factory floors where the oldest asset in the building is often the one that matters most.
7 of our 19 case studies are in this sector.
All 19 case studies What we meter in Manufacturing: automotive, plastics & rubber
A real page with its own address (§B.2), reachable from the Industries hub, the sector page and the library’s industry rail.
What we found in factories like these.
WaterManufacturing: automotive, plastics & rubber
Chiller circuit leak isolated without a shutdown
An automotive factory
A leaking cooling loop found and isolated with the line still running.
1 loopisolated
Compressed airManufacturing: automotive, plastics & rubberMetal Fabrication & Finishing
Compressed air leaks in a stamping operation
A Tier 2 automotive stamping factory
The most expensive utility per unit of work, leaking into an empty building overnight.
20–30%of compressor output
Predictive maintenanceBulk Handling & Rail LogisticsManufacturing: automotive, plastics & rubber
Conveyor drive bearing degradation caught six weeks early
A bulk handling facility
A bearing changed its signature about six weeks before it would have seized.
6 weeksof warning
Cooling towersWaterManufacturing: automotive, plastics & rubberBuilding Materials, Concrete & Aggregates
Cooling tower blowdown optimization
A plastics manufacturing factory
Blowdown running on a timer instead of on conductivity, discharging good water.
1 setpointchanged
Natural gasBuilding Materials, Concrete & AggregatesManufacturing: automotive, plastics & rubber
A 1970s boiler brought onto the dashboard
A heavy manufacturing factory
A fifty-year-old boiler, integrated through its 4-20 mA output. Nothing was ripped out.
4-20 mAintegration
Energy & electricityManufacturing: automotive, plastics & rubber
Three factories, one unit of production, one outlier
A manufacturer with three factories
Same product, same equipment, and one factory used about 40% more energy per unit.
~40%more energy per unit
Temperature & humidityMetal Fabrication & FinishingManufacturing: automotive, plastics & rubber
Welding bay CO and CO₂ monitoring
A metal fabrication shop
Air quality in the welding bay, watched continuously instead of checked quarterly.
Continuousvs. quarterly
We would like to see what these numbers look like in your factory.
Bring us a shift and a stack of bills. We will walk the plant with your team, point at what is worth metering first, and put a figure beside it.
Book a site visitRun the numbers
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