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
See what these numbers look like in your factory.
Bring us a shift and a stack of bills. We will walk the floor with your team, point at what is worth metering first, and put a figure beside it.
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