General details
EDIHs involved
Challenges
IBAK, a company specialising in sewer inspection and rehabilitation solutions, encountered a serious issue with one of its key components—a gearbox that produced excessive noise levels exceeding 100 decibels. This noise posed a significant environmental and occupational health risk. Despite multiple design changes and material adjustments, the root cause of the noise could not be identified, leading to a costly and resource-intensive trial-and-error process.
Solutions
During a technology transfer event hosted by Kiel University of Applied Sciences, IBAK’s team learned about a digital vibration sensor typically used in CNC machining for monitoring vibrations. Inspired by this, they partnered with EDIH.SH to test whether this sensor could diagnose the noise issue in their gearbox.
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Application: The sensor was magnetically attached to various points on the gearbox to measure vibrations, helping identify the specific area where the noise was originating.
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Outcome: The sensor revealed that the gearbox housing was vibrating at the same frequency as the toothed belt, pinpointing the exact cause of the noise.
Results and Benefits
Targeted Adjustments:
With the source of the noise identified, IBAK could focus on making precise adjustments, such as switching to a different type of belt or modifying the gearbox housing to dampen vibrations.
Resource Savings:
This targeted approach led to significant reductions in time, cost, and material waste. The company estimates savings of around €10,000.
Health and Environmental Impact:
By addressing the noise issue, IBAK is expected to reduce the noise level to a more manageable 70 decibels, improving working conditions for operators and reducing environmental noise pollution.
Perceived social/economic impact
Cost Savings:
By efficiently addressing the noise problem, IBAK saved approximately €10,000 and reduced the need for ongoing, costly adjustments.
Strengthened Partnerships:
The collaboration with Kiel University of Applied Sciences has led to closer ties and opened up opportunities for future projects.
Improved Working Conditions:
The anticipated noise reduction to 70 decibels will create a safer and more comfortable environment for employees and reduce noise pollution for nearby residents.
Measurable data
The primary goal was not just noise reduction but finding a more efficient solution to identify the noise source. With this success, IBAK now saves considerable resources—money, materials, time, and manpower. The findings also have broader implications, including improved competitiveness, higher employee satisfaction, and better public perception of the company.
DMA score and results - Stage 0
The score of 76% indicates a high level of digital maturity, significantly surpassing all comparison benchmarks. This performance is notably higher than the average for personal services in Germany (48%), as well as the EU average for personal services (36%). It also exceeds the EU average for small-sized enterprises (42%) and the average for similarly sized peers in the personal services sector in Germany (49%). Additionally, the score is well above the overall average of all respondents (40%), underscoring a strong competitive edge in digital maturity and positioning the organisation as a leader in its sector.
Lessons learned
Do’s:
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Leverage External Knowledge: Engage with external partners and events, like technology transfer sessions, to gain fresh perspectives and innovative solutions.
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Think Outside the Box: Be open to applying technologies from different fields to solve your specific challenges.
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Encourage Employee Creativity: Give your team the freedom to explore new ideas and attend events that can inspire innovative thinking.
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Focus on Data: Use sensors and other digital tools to gather high-quality data that can lead to actionable insights.
Don’ts:
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Avoid Solely Relying on Trial-and-Error: This approach can be time-consuming and costly. Instead, seek more precise and data-driven methods.
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Don’t Overlook Simple Solutions: Sometimes, the answer lies in straightforward adjustments rather than complex redesigns.
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Don’t Dismiss New Technology: Stay informed about technological advancements and consider how they might address your current challenges.
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Don’t Limit Cross-Disciplinary Thinking: Innovation often comes from integrating ideas across different fields or industries.
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