How Ultrasound Technology Improved Bearing Lubrication for Constellium

About Constellium
Constellium is a global manufacturer of innovative and high-value-added aluminum products primarily dedicated to aerospace, automotive, and packaging markets. With 27 manufacturing sites across Europe, North and Central America, and China, Constellium operates through three business units - Aerospace and Transportation (A&T), Packaging and Automotive Rolled Products (P&ARP), and Automotive Structures and Industry (AS&I) - to respond to the fast-evolving market needs. Constellium’s Technology Center (C-TEC),l ocated in Voreppe, France, and its new hub in Plymouth, MI, U.S., are responsible for designing and developing advanced aluminum alloys and solutions.

The Problem
Constellium’s Ravenswood, WV plant was facing critical failures on combustion fan bearings, motor failures due to improper greasing, malfunctioning auto-lubricators, alignment inconsistencies, compressed air leaks, and more. They were relying on time-based preventive maintenance for its lubrication program, which proved to be an issue since there is no textbook lubrication schedule that eliminates unplanned downtime and failure. Moreover, too much lubrication is just as harmful as too little. Condition-based predictive maintenance proved to be more dependable since it eliminated lubrication guesswork and listened to equipment.

The Solution
Condition-based maintenance, combined with ultrasound technology, enabled Constellium to listen to its assets and eliminate the guesswork that comes with time-based lubrication. Ultrasound equipment helped the team listen to the assets and determine exactly how much grease the bearings needed, which drastically reduced unexpected downtime and prolonged the life of the assets. The team matured its ultrasound program over time and moved to the Ultraprobe 15,000, paired with made-for-purpose grease caddies for condition-based lubrication.

The Results
After implementing condition-based maintenance with ultrasound technology, Constellium noticed a significant reduction in unplanned downtime, a decrease in the cost of contracting work to third parties, improved lubrication practices on critical assets, and improved machine efficiency. The return on investment was immediate, and the team was able to make positive improvements to its maintenance strategy.

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