Eliminating Bearing Failures: How Strategic Partnerships Boosted Reliability and Saved $230K

A leading U.S. steel manufacturer faced a critical problem: a bearing on the outboard roll of a dual‑line coating system failed six times in just four months, causing repeated unscheduled downtime and lost productivity. Despite thorough vibration monitoring showing no obvious issues, the bearing failed again within weeks of replacement.

Root‑cause analysis required a collaboration between the plant’s reliability engineers, locally based industry specialists, and the manufacturer’s own maintenance staff. Together they identified axial thrust on the roll—a load the original bearing could not tolerate—as the culprit.

The solution was a switch to a toroidal roller bearing engineered for axial displacement and a revised lubrication program. Since the change, the line has operated without bearing failure or interruption. The project delivered over $230,000 in cost savings within the first year, with a payback period of just one month.

Creating Value

When reliability experts become embedded members of a maintenance team, the benefits extend far beyond immediate fixes:

• Improved communication and knowledge transfer between operations and specialists.
• Comprehensive root‑cause analysis that prevents recurrence of failures.
• Targeted training for maintenance staff, lowering total cost of ownership.
• Continuous improvement of routine maintenance procedures.

A U.S. taconite mine demonstrates similar gains. Dedicated reliability engineers conduct weekly predictive‑maintenance routes, while industry specialists perform damage analysis, root‑cause reporting, and on‑site training. Key outcomes include:

• Removal of contaminants from conveyor pulley bearings via upgraded sealing systems.
• Redesign of mill pinion bearing housings and custom seals to eliminate contaminant ingress and improve support.
• Training on proper hydraulic‑assist installation for dust‑collector fans, enhancing reliability.

Making the Grade

Choosing the right reliability partner is critical. Consider these questions before engagement:

• Can the provider demonstrate industry‑specific expertise?
• Do they offer comprehensive resources—from analysis tools to training?
• Do they understand lifecycle asset management?
• Can they respond swiftly to unexpected failures?
• Will they integrate seamlessly with existing maintenance functions?
• Will they provide thorough written documentation of problems and solutions?
• Do they have robust supplier relationships for timely parts delivery?
• Can they measure program progress meaningfully?
• Will they demonstrably reduce total operating costs?

Answering these questions ensures you partner with a team capable of sustaining continuous improvement and delivering both immediate and long‑term benefits.

About the Authors

Andy Rein – Director, SKF Reliability Systems, Schaumburg, Ill. Andrew.Rein@skf.com

James A. Oliver – Director, Sales Support Engineering, SKF USA Inc., Lansdale, Pa. james.a.oliver@skf.com