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Bodycote

• The Bodycote facility was able to measure it’s total gas consumption, but it was unable to measure how much gas was being used at each of its furnaces.
• Without a clear understanding of per furnace gas usage, managers were unable to effectively increase plant efficiency, diminishing the plant’s profitability.

• Working with an ISA100 Wireless supplier, Bodycote defined the following parameters for each IQ furnace:
  • Furnace total gas usage per load
  • Furnace efficiency
  • Plant utility costs
  • Heat treat area gas usage as compared to facility use
• ISA100 Wireless transmitters ranged 0-100” H20 were installed on each of the four furnaces main gas lines to sense the actual CfH, as well as summing Cf per second using four virtual pens.

• Achieved better understanding of associated costs to run specific products in furnaces.
• Enabled the development of a baseline for future plant improvement and proactive maintenance.
• Improved reliability of gas usage and cost data.
• Improved efficiency of four furnaces due to better data analysis.
• Increased worker safety through remote furnace monitoring.
• Simplified scheduling of furnace preventative maintenance.