This paper presents four case studies documenting the time and money that heat treaters have saved with the help of predictive maintenance tools. In one case, a heat treater avoided potential catastrophic melting of a heating element and several hangers when predictive maintenance software guided the operator to a broken ceramic in a specific heating zone. In another case, a commercial heat treater was alerted to a low kW reading, indicating a heater failure on a diffusion pump, which would have led to the contamination of a vacuum furnace if not addressed in a timely manner. Situations involving a failing motor on a quench tank and the degradation of furnace insulation are also discussed. Cost comparisons, with and without predictive maintenance, are included in three of the four studies.

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