FPT Powertrain: +30.4% tool life on a €4.6M/year station
Injector bore finishing. Tool overconsumption of €4.6M a year across the site, irregular wear, and interruptions nobody saw coming. Lesly took tool life from 230 to 300 minutes.
- Customer : FPT Powertrain — automotive powertrain
- Equipment : Boring machine tool
- Operation : Injector bore finishing
- Stake : Tool overconsumption — €4.6M/year across the site
- Module : @MachineHealth
The field challenge
On this station the tool is the dominant cost line: €4.6M a year of consumption at site level. Wear was irregular, maintenance insufficiently proactive, and interruptions arrived without warning. Every minute of tool life gained converts straight into euros — one of the rare cases where ROI needs no explaining.
- +30.4% — Tool lifetime
- 230 → 300 — Minutes per tool
- €4.6M — Annual site consumption
- 7 days — Ahead of temperature sensors
Seven days ahead of the temperature sensors
The most telling result is not the lifetime gain: it is the spindle grease shortage detected seven days before the temperature sensors raised the alarm. Physical monitoring waits for the symptom to become thermal. KM0 sees the drift in axis torques and currents long before heat betrays the fault. On a station at this cost level, seven days of lead time change the very nature of the intervention.
+30.4% tool life on a €4.6M/year station is a direct savings lever. Detecting grease shortage 7 days before the temperature sensors proves, with figures, Lesly’s superiority over classic physical monitoring.
Decisive argument — ref. DAS-DIA-160626-UC-001
The gain is immediately quantifiable
230 to 300 minutes per tool against a known annual consumption: the arithmetic needs no assumptions.
Anticipation before tolerance
Faults are flagged before tolerances are exceeded, therefore before the first out-of-spec part.
Superiority demonstrated, not claimed
Seven days ahead of installed physical sensors: the comparison was run on the same machine.
If your tooling cost runs into millions, the payback calculation is immediate. We run it with you on your own figures.