Hungary: Cost savings by digitalisation at the largest Hungarian exporter
The advancement and the value of the manufacturing technology of GE Power Veresegyház is well demonstrated by the fact that 50% of the maintenance costs of the plant operating 120 pieces of machining equipment is incurred by the continuous maintenance and replacement of six high-value plasma spraying apparatus. With the plasma sprays, a ceramic shielding layer is blown to parts of gas turbines exposed to high temperatures.
“Thank to digitalisation, by today it has become very cheap to collect, process and analyse data gained from the operation of high value machinery and equipment. This brings enormous change to the former rather inaccurate maintenance practices based on statistical models.”- said Gergő Lencsés, plant manager of GE Power Veresegyház.
Reducing maintenance costs
In the frame of the recently closed development, GE Power Veresegyház measured the operation of the plasma spraying apparatus with sonic analysers and noise levels typical of normal and pre-malfunction operation have been defined on the basis of the measurements. Engineers of the factory have tripled the life span of the plasma spraying machinery by altering operation parameters based on measurement results.
This single digital development, based on data analysis, in itself has reduced maintenance costs by nearly 100 million Forints.
Key to the restructuring of GE is Predix, the world’s first and so far only cloud based platform developed for the industry, which was introduced by GE in February, 2016. Predix helps GE itself and GE customers in energetics, healthcare, automotive, chemicals, transport, oil and gas and machine industry to improve operation and production efficiency of their high value assets by solutions in data analytics.
There is enormous potential in increasing productivity. According to GE’s calculations, if all European costs were reduced by a mere 1% by the means of increasing efficiency and productivity, the joint GDP of the EU could grow by 2,8 billion Euros by 2030, which equals with the quarter of the present size of the Euro-zone.
This article was first published onmaschinenmarkt.international.