Often overlooked, fasteners – the screws, nuts, and bolts – are the essential building blocks of a well-functioning machine. Just as a pre-race shoe check is crucial for a runner, a regular fastener inspection is paramount in preventing malfunctions and breakdowns. A single faulty fastener can have a domino effect, causing misalignment or worse, even a catastrophic failure. Monitoring and replacing worn or damaged fasteners pre-emptively ensures the machine operates at its best.

The Challenge

Our client had a BIS audit scheduled for their machinery, which was covered under an AMC. Despite our recommendations to replace certain parts beforehand for optimal performance, the client opted to defer. Unfortunately, the audit date couldn’t be adjusted, and coincided with an unexpected breakdown of the critical machine.

  • Reduced Machine Capacity: The machine, with a maximum capacity of 2000 KN, was able to function at a reduced capacity, handling loads up to 1100 KN. This significantly impacted its overall performance during the audit.
  • PCIE card replaced with controller : A malfunctioning PCIE card and control box rendered software-based operation and sample holding at specific loads impossible. This created additional challenges during the audit process.
  • Load Cell Drift: The load cell exhibited a drift of 300 KN, displaying an incorrect zero value of 300 KN. This introduced data inaccuracies that could potentially affect audit results.

The Solution

Our initial visit to the site revealed the need for parts replacement to ensure proper machine operation. During the process of addressing these parts, further problems were identified.
A leak was initially discovered within the system. After containing the leak, the team discovered a problem with the hydraulic pump, which emerged just a day before the BIS audit. The malfunctioning pump was promptly replaced, restoring the machine to full operating capacity.
Due to unforeseen delays with the urgently ordered control box from our Chinese vendor, our team’s quick thinking overcame the delay in obtaining the control box. They sourced a compatible unit from another client, ensuring timely machine operation. Replacing the load cell presented a significant challenge due to an extended lead time of 8-10 weeks. To address this, we opted for calibration instead. This calibration confirmed consistent readings within the relevant range of 300 KN to 1700 KN. Knowing the client’s typical load requirement of 1200 KN, we were able to confidently complete testing using the existing, calibrated load cell.
The tight deadline set by the customer during the implementation phase posed significant challenges, necessitating completion of all tasks, including parts sourcing, within a week.
We sourced O Rings and seals locally within two days. Despite transporter delays, our vendor promptly dispatched the PCIE card and Control Box. To compensate, we sourced these parts from another customer’s stock. Our service engineer arranged urgent dispatch from Delhi to Villupuram. The shipment arrived at the site by 10:30 PM. The customer arranged the hydraulic pump late at night before the audit. Our team mobilized immediately, working until 7:00 AM to ensure machine readiness. Through-out the process, our team remained on-site until the successful completion of the BIS audit, ensuring that all necessary tasks were carried out efficiently and effectively.


  • Client-Centric Approach: Prioritized the client’s BIS audit success by treating it as our top objective.
  • Resourceful Problem-Solving: Exceeded client expectations through proactive resource mobilization for a timely solution.
  • Technical Expertise & Collaboration: Identified additional machine issues and leveraged on-site resources to achieve an efficient resolution.

Send an Enquiry