Smart Performance Program

Success through Collective Competence

S m a r t

P e r f o r m a n c e

P r o g r a m

Success through Collective Competence

The Smart Performance Program

was brought into being in order to
fulfil this demanding task. With the
aid of specially trained and highly
qualified experts with excellent
market sector knowledge, the Field
Service Engineers (FSEs), we provide
our customers with individual and
comprehensive support.
The FSEs act as partners to support
the company not only from a distance
but on site as well in the customers
own factory. This applies irrespective
of whether the customer requires
help on an individual problem or a
complete solution for his plant
machinery.

A high level of plant availability is a

decisive factor in determining the
success of industrial enterprises.
Against the background of the
growing complexity of machinery,
there is an ongoing increase in the
requirements placed on technology
and maintenance. As a pioneer in
the rolling bearing industry, the
Schaeffler Group has long supported
its customers through innovative
products and customised services.
A worldwide presence, top quality,
customer proximity, product
innovations and state of the art
technologies define our mindset
and secure the success of our
customers.

The Smart Performance Program is a

further milestone in the development
of the Schaeffler Group. Through
this overarching concept, we are
improving the networking of our
broad range of products and services
and can serve our customers more
efficiently through our focussed
competences.
Solving problems in a rapid and
targeted way and optimising
processes represents an important
challenge for us. Through innovative
products and solutions relating to
rolling bearings that are matched to
our customers and their markets
together with a worldwide network
combining production and technical
service, we help companies to
achieve higher performance.

In both cases, the FSE first carries

out an inspection of the critical
machines. In consultation with the
customer, he then prepares a plan
for eliminating the existing weak
points in the best possible way and
gives support as required in all
phases of implementing a dedicated
and comprehensive solution.

The customer benefits of working with the FSE

Advance
development
Testing

Rolling bearing
engineering

Materials
Coatings

Tribology

Know-how
relating to rolling
bearings
Rolling bearing
reconditioning

Mounting
Maintenance
Inspection
Assessment
Troubleshooting

Der Field Service Engineer one

partner for all your requirements
The FSE knows the plant, processes
and problems of his customers and
has comprehensive rolling bearing
know-how, extensive process
knowledge and is an expert in
the condition monitoring and
maintenance of machinery and
plant. He assists the customer in
increasing production efficiency and
achieving competitive advantage.
By means of regular training, we
ensure that our FSEs are always
familiar with the latest developments
and technologies. Since the FSEs
work with all areas of the Schaeffler
Group, customers always benefit
from the broad knowledge of a
global company without the need
to change contact persons.
FSEs ensure good customer proximity
anywhere in the world, flexibility
and expert service.

Through proactive maintenance, plant

is kept in an optimum condition.
As a result, plant availability is
increased and unplanned downtime
is avoided.
In relation to spare parts procurement, the FSEs working together
with Schaeffler Group experts help
customers to make the right decision.

Condition
monitoring

Technical
consultancy

FSEs offer services that allow

proactive maintenance and comprehensive technical and economic
assessment of all (plant) components
over their entire life cycle, from
procurement to replacement or
reconditioning.

Customer training

Our portfolio
Access to a wide range of products
and services relating to rolling
bearings
In spite of the wide variety
everything from a single source
one face to the customer
Excellent advisory competence
and continuous support
Innovative (plant) concepts with
high quality products
Reduction in total plant costs
(Total Cost of Ownership)
Application-specific service
packages for individual customer
requirements
High plant availability with
optimised maintenance costs
Rapid response by FSEs on site
Continuous support on all matters
relating to rolling bearings
Optimisation of delivery times
through stock management of
sector-specific special bearings

C o r e

C o m p e t e n c e s

Development and engineering

Rolling bearing engineering

Under the FAG and INA brands,
Schaeffler Group Industrial develops
and manufactures high quality
rolling bearings, plain bearings,
spherical plain bearings, slewing
rings and linear guidance systems
for machine building. We thus have
a comprehensive product portfolio,
one of the widest in the rolling
bearing industry. With approx.
40 000 catalogue products manu factured as standard, applications
across some 60 industrial sectors
can be covered. In addition, we
work in partnership with our
customers to develop a large number
of application-specific solutions
that can give functionally and
economically effective solutions to
complex bearing technology tasks.
In total, we offer some 160 000
bearing products to industry.
Advance development
As a company looking to the future,
the Schaeffler Group invests heavily
in research and development.
Our engineers are characterised by
creative engineering, often pursuing
unconventional approaches.
Questioning the status quo,
venturing down unusual paths and
exploring different perspectives are
preconditions for the development
of innovative, extraordinary ideas.
In close consultation with our
customers, we are continually
achieving new technically, economically and ecologically persuasive
solutions and thus generating
competitive advantages.

Testing
In our test centre, we thoroughly
test every aspect of new developments.
For example, the Schweinfurt site
has an area of approx. 7 000 m 2
for testing both the function of
completely assembled rolling
bearings and the individual
components and materials.
With about 100 different types of
test rigs developed in-house for
bearings of different types and
sizes, we process some 700 test
commissions each year.

Materials technology and tribology

Materials
The Schaeffler Group range includes
dedicated materials, heat treatments
and coating systems that give
excellent mechanical characteristics
such as protection against wear and
thus ensure significantly increased
bearing life.
Special steels such as Cronidur, the
high performance plastic PEEK,
ceramics and hardened amagnetic
rolling bearing steel are combined
with each other to achieve maximum
customer benefit. The product
portfolio is broadly based and is
oriented to the application aims of
customers: rolling elements made
from ceramic or steel, cages made
from brass, sheet steel or PEEK,
bearing rings made from case
hardened steel and many others.

Coatings
Coatings influence a wide range
of bearing characteristics: wear,
corrosion resistance, running-in
behaviour, emergency running

characteristics, media resistance,

behaviour under lubricant starvation
etc. If the principal requirement is for
particularly effective anti-corrosion
protection, for example, use is
made of Corrotect , a cathodic
anti-rust protection system applied
by electroplating. TRIONDUR coating
systems give protection where
consistently high tribomechanical
loads and lubricant starvation are
anticipated. In contact areas under
high load, PFTE coatings ensure
good sliding behaviour with a very
low coefficient of friction.

Tribology
Lubrication has a considerable
influence on the performance
capability and operating life of a
bearing. The choice of lubricant
(oil or grease) is dependent on the
operating conditions present at the
bearing position. With the Arcanol
range, the Schaeffler Group offers a
selection of rolling bearing greases
that have been tested in our in-house
test facility under conditions derived
from practice.

The subject of media-lubricated

bearings relates to solutions in
which the bearings are used in
various media such as water, steam,
liquid gas or refrigerants.

C o r e

C o m p e t e n c e s

Maintenance and condition monitoring

Tools and systems

A wide range of tools and ancillary
devices is offered by FAG Industrial
Services (FIS), which is reponsible
for complete customer services
covering the FAG and INA brands in
the industrial market. The product
portfolio covers tools for mounting
and dismounting, products for
condition monitoring and alignment
and a large selection of high
performance greases (Arcanol).
FIS is thus the expert contact for
professional solutions relating to
maintenance.

Online and offline monitoring

Mounting, maintenance, inspection

and assessment
This service covers the mounting,
maintenance, inspection and
assessment of rolling bearings by
specially trained experts across
numerous market sectors.
Our mounting personnel carry out
skilled mounting and dismounting
of all types of rolling bearings.
During the maintenance and
inspection operations, the bearings
are checked for functionality,
lubricated and wear parts are
replaced as required. For longer
term storage of bearings, we offer
long term preservation together with
appropriate special packaging.

Condition monitoring allows

assessment of changes in the
vibration behaviour of plant over
time. In this way, it is possible to
detect incipient damage at an
early stage and thereby prevent
unplanned downtime. The FSE first
helps our customers to find the most
appropriate monitoring solution for
their plant and then assists in its
installation and software configur ation. During the operating phase,
he supports customers in the
upkeep and maintenance of the
system on site.
FIS offers the online and offline
measuring systems necessary for
monitoring. In addition, there is the
option of remote monitoring by the
certified FIS Service Center.

Troubleshooting and rolling bearing reconditioning

Rapid assistance
As an alternative to continuous
monitoring, we also offer regular
individual measurements and
troubleshooting measures.
If malfunctions occur on a machine,
for example, a detailed defect
analysis must be carried out rapidly
in order to avoid long, costly machine
downtime and lost production.
The causes of the malfunction can
be quickly identified by measurements on running subassemblies.
The defects often become apparent
through, for example, changes in
vibration behaviour or unusual
temperature patterns. The FSE is
familiar with all common diagnosis
methods (vibration measurement,
modal analysis, torque/force
measurement, endoscopy, thermo graphy etc.) and knows exactly which
method he can used to reliably
identify the cause of the defect.

Lower costs
The reconditioning of rolling bearings
and rolling bearing units is a core
competences of FIS and is offered
at several certifiied locations

worldwide. The services for rolling

bearings of all types apply irrespective of manufacturer and are not
restricted to Schaeffler Group

products. For companies, this offers

considerable potential for cost
reduction in maintenance, since
the costs and delivery time for
reconditioning are significantly
lower than those for a comparable
new bearing. In individual cases,
customers may also receive the
same warranty on the reconditioned
bearing as on a new bearing.

C o r e

C o m p e t e n c e s

From practitioners for practitioners

Customer training
The comprehensive training portfolio
of the Schaeffler Group allows
customers worldwide to benefit from
the many years of experience gained
by Schaeffler employees and build
up their own knowledge of products
and applications relating to rolling
bearings.
The FIS training portfolio covers
the areas of mounting, lubrication,
alignment, condition monitoring
and maintenance management.
In the form of classroom teaching,
both standard and customer-specific
training is offered, during which
experienced trainers communicate
their practice-based knowledge
using real demonstration materials.

Technical consultancy
Technical consultancy relating to the
life cycle of rotating components is
one of the main activities of the
FSEs, who always work in close
consultation with Schaeffler Group
experts.
In the concept phase of the plant,
they assist customers in the
selection and layout of bearings.
During the operating phase, they
provide support in the planning and
implementation of maintenance
activities. If it is ultimately necessary
to replace a bearing or other
component, the FSEs advise the
customer on the selection of the
replacement part appropriate to his
purposes.
During the enture period, the FSEs
are always focussed on finding the
most efficient solution for the

customer as well as identifying

and eliminating hidden costs.
The focussed competences in the
Smart Performance Program are
critical factors for success.

For all those who wish to take

their first steps in rolling bearing
technology quickly and securely on
a self-taught basis, the Schaeffler
learning platform medias -campus
is the right solution.

K e y

I n d u s t r y

S e c t o r s

Pulp and paper

Comprehensive competence
Schaeffler Group Industrial is,
through its brands FAG and INA,
one of the worlds leading
manufacturers of rolling and
plain bearings. In close partnership with the manufacturers and
operators of plant and machinery,
carefully matched solutions are
developed for bearing appli cations in all industrial sectors.
In particular, it has comprehensive experience in sectors
including pulp and paper, raw
material extraction and processing, cement, oil and gas, steel
and non-ferrous metals and
wind power.
Furthermore, we also have more
than 100 years of experience in
the rail sector including our own
TV-approved inspection facility
for bearing arrangements and a
rolling bearing reconditioning
service for axlebox bearings,
special products and services
for the marine industry etc.
Having worked for many years
with various market sectors,
we know the needs of these
branches of industry and are in
a position to develop optimised
solutions matched to specific
sectors.

Bearing technology and service for

the pulp and paper industry are
brought together in the pulp and
paper sector. Capital-intensive
production plants must offer
constant availability, on the basis
of the highest plant quality and an
intelligent life cycle service that
leaves nothing to chance.
This creates a requirement for
reliable products and services.
Having worked over decades
with renowned paper machinery
manufacturers and paper plants, we
have outstanding expert know-how.
This is continuously fed into the
development and selection of rolling
bearings and the implementation
of services for the pulp and paper
industry.

Examples from the Schaeffler

portfolio:
Cost savings through mounting
of extremely long life FAG X-life
spherical roller bearings
Development and mounting of
FAG anti-slippage self-aligning
bearings for CD profile control
rolls
Online condition monitoring
using FAG VibroCheck on a paper
machine
Modal analysis of gearboxes and
motors

K e y

I n d u s t r y

S e c t o r s

Raw material extraction and processing

Thanks to our comprehensive

know-how, we can always offer
our customers the right bearings,
housings, accessories and services.

Examples from the Schaeffler

portfolio:
Development and delivery of
rolling bearings for vertical mills
for use in clinker and coal
processing
Reconditioning of bearings for
tunnel boring machines
Online vibration monitoring of
bucket wheel excavators, belt
conveyors as well as tube and
SAG mills

Significant technical advances are

continually being made in the fields
of mining, extraction of crude oil
and natural gas as well as in the
processing of raw materials. For this,
rolling bearings, plain bearings
and spherical plain bearings are
essential. Harsh operating and
environmental conditions require
extremely sturdy bearings as well
as robust, sealed housings.
Based on many years of research
and development as well as intensive
exchange of information and
experience with manufacturers and

10

plant operators, we are continually

improving our bearings and services
in the raw material extraction and
processing sector. One of our core
strengths lies in the development of
customer-specific large size bearings
for applications in the cement or
crude oil industries.

Cement, oil and gas

Cement
One of our core strengths is the
development of customer-specific
large size bearings and service
solutions for the cement industry.
Rolling bearings in cement production
applications are subjected to
extremely harsh conditions such
as dust, high temperatures and
shocks. In order to fulfil these
requirements, such bearings have
very high load carrying capacities
due to the use of the maximum
possible number of rolling elements
and coating systems matched to the
application.
Customised monitoring solutions,
e.g. for mill drives, also ensure a
reduction in unplanned downtime.

Examples from the Schaeffler

portfolio:
Online vibration monitoring of
tube mills in the cement industry

Spherical roller bearings with a

thin layer chromium coating for
vibrating screen machinery in
accordance with specification T41D

Oil and gas

Schaeffler Group Industrial, working
with FIS, offers solutions for
almost all applications in the oil
and gas industry, both upstream
and downstream.

Temperature and vibration

monitoring in refineries, e.g. on
motors, fans, pumps or ventilators
(online vibration monitoring also
in EX-protected areas)

Examples from the Schaeffler

portfolio:
Condition monitoring of bearing
arrangements in fluid pumps or
top drives
Offline condition monitoring for
offshore and onshore applications
Reconditioning of rolling bearings,
e.g. for rotary tables, fluid pumps,
swivel and turret systems
Media-lubricated bearings for LNG
pumps

11

K e y

I n d u s t r y

S e c t o r s

Steel and non-ferrous metals

In relation to the steel and

non-ferrous metals sector, Schaeffler
Group Industrial has expert
knowledge of bearing technology,
comprehensive know-how in
metallurgical works and rolling mill
applications and many years of
experience in working with the
steel industry. Due to the extreme
operating conditions, rolling bearings
in this sector are severely prone to
wear and require particularly robust
construction and care. With a view
to maximum quality and availability,
the Schaeffler Group offers OEMs
and plant operators bearing solutions
for all bearing positions in plant for
the production and forming of steel
and non-ferrous metals. This offer
is complemented by products and
services for mounting, lubrication,
alignment and condition monitoring.

12

Examples from the Schaeffler

portfolio:
Development of dedicated full
complement cylindrical roller
bearings and special spherical
roller bearings for continuous
casting plant
Sealed four row tapered roller
bearing for work and back-up rolls
Reconditioning of cylindrical roller
bearings for roughing stands
Online monitoring of hot rolled
wide strip plant
Customer-specific training, e.g. on
mounting of work roll bearings

Wind power

In wind power plant, central

importance is attached to the
bearing arrangement for the rotor
shaft and the blade bearing arrangements. These are directly exposed
to all the forces and moments
induced by the wind. The rolling
bearings are subjected to highly
dynamic loads and operating
conditions. In each case, the engin eers of Schaeffler Group Industrial
develop the most efficient bearing
arrangement in partnership with
their customers.
Dedicated monitoring solutions
from the service subsidiary FIS
ensure problem-free functionality
of the main bearing arrangement as
well as the whole drive train.

Examples from the Schaeffler

portfolio:
Development of rotor main bearings
for turbines from 220 kW up to
innovative single bearing concepts
in the multi-megawatt class
Mounting of main, gearbox and
blade bearing arrangements
Monitoring of the whole drive
train
Reconditioning of main and blade
bearing arrangements
Customer-specific training on
monitoring technology in wind
turbines

13

S m a r t

P e r f o r m a n c e

P r o g r a m

Global competence

Do you want to know more about the

Smart Performance Program?
Then contact us by e-mail
info@smartperformanceprogram.com
or visit our homepage
www.smartperformanceprogram.com
Thats where you will find
Information about the concept
Smart Performance Solutions
Contact details for worldwide
contact persons

14

Further information about the

company and our products can be
found on the Web pages of the
Schaeffler Group:
www.fag.com
www.fis-services.com
www.schaeffler.com

In addition, you can order from a

wide range of publications and
brochures presented there.

What else can we do to convince you?

MATNR 034710779-0000 / FIS001 / GB-D / 2009021.5 / Printed in Germany by Weppert

Every care has been taken to ensure the

correctness of the information contained
FAG Industrial Services GmbH
Kaiserstrae 100
Schaeffler KG

52134 Herzogenrath (Germany)

Postfach 1260

Phone

+49 2407 9149 - 66

97419 Schweinfurt (Germany)

Fax

+49 2407 9149 - 59

Georg-Schfer-Strae 30

E-mail

info@fis-services.com

97421 Schweinfurt

Internet www.fis-services.com

in this publication but no liability can be

assumed for any incorrect or incomplete
data. We reserve the right to make
technical modifications.
Schaeffler KG 2009, February
Reproduction in whole or in part without
our authorisation is prohibited.
FIS001 GB-D