In an average of approx. 7.5 seconds, the two fully automated tyre assembly lines of MC Syncro Supply GmbH mount a tyre on a rim. The plants usually run 5 days a week in a 3-shift system, which adds up to about 120 hours per week. At the so-called tyre soaping station, the diameter of the tyre is determined from the inside, while the inner bead of the tyre is being moistened by brushing with soap. To enable this, soap flows into the brushes from above. The excess soap runs back into the storage tank over a trough. The conveyance of the tyre in and out of the tyre soaping station runs over toothed belts which are clamped on two mounted brass shafts.
Due to the soap, the grease was washed out over time even from encapsulated bearings. Especially for metallic bearings lubrication with, for example, grease or oil is essential for a long service life and optimum performance of the bearings during operation.
The result was that the metal bearings jammed and the shaft continued to rotate. This then wore out within a very short time. The damage costed 6 hours in repair time and led to the replacement of all defective components (2 shafts, 4 bearings, 2 toothed belts) at a cost of €610. This repair had to be done on each machine twice a year. The costs for the repairs and the machine failure added up to several thousand euros.