Aqua's pump manufacturer uses QC20-W ballbar to reduce production and maintenance

Pump manufacturers have not only extended the lifespan of machine tools, but also managed to cut unplanned downtime by 10%. The Renishaw QC20-W ballbar system has gained recognition as a key preventive maintenance tool for both new and existing machine tools. As a subsidiary of the Aqua Group and one of Asia’s leading pump manufacturers, Aquasub Engineering in Coimbatore, India, has adopted the QC20-W to lower production and maintenance costs, boost productivity, and reduce waste.  As the manufacturing industry increasingly embraces Total Production Maintenance (TPM), Aquasub sought innovative solutions. When they learned about the new Renishaw QC20-W wireless ballbar system, they invited Renishaw for a product demonstration. The results were impressive—showing high accuracy and a wide range of data on various machine tool errors. The QC20-W can detect up to 18 different geometric and dynamic errors, offering a more reliable diagnosis than their previous methods. The successful demonstration of the QC20-W on Aquasub’s machines not only built trust but also convinced them that this device would be an essential part of their TPM program. **There are many benefits to using the QC20-W**  Mr. K Senthil Kumar, General Manager of Aquasub Engineering To avoid unnecessary purchases of new machine tools, Aquasub aims to maintain its 200 existing machines, most of which have been in operation for over 25 years. Mr. Kumar explained, “We prefer to maintain and restore old machines rather than buy new ones. It's more cost-effective.”  “Extending the life of our machines improves performance and reduces unplanned downtime. This enhances efficiency and keeps the machines in good condition. Our machine downtime has dropped by 10%. We now collect detailed information on each machine, allowing operators to quickly identify and address even minor issues. We also perform regular QC20-W testing to ensure consistent performance. Now we can complete three plane tests in one setup, cutting maintenance inspection time by 20%.” **Regular testing is critical** Mr. Kumar added, “We store test data in the Ballbar 20 software, enabling us to create maintenance schedules and take action before quality issues arise. If the machine is in good condition, the workpiece quality remains stable. Since integrating the QC20-W into our maintenance program, waste and defective products have significantly decreased.” Even new machines are tested with the QC20-W upon installation, as even new equipment can produce scrap due to transport or installation damage. **The right tool for the job** The Aqua Group offers a wide range of products used in critical applications like agriculture, urban water supply, and industrial systems. With 4,000 pumps produced daily, the reliability of their 200 machines is crucial for timely delivery.  The group focuses on continuous improvement through enhanced knowledge, technology development, and process optimization. By implementing a comprehensive TPM program, they ensure consistent quality and identify areas for further growth. Mr. Kumar concluded, “Previously, we relied on engineers’ subjective opinions, which led to a high risk of human error. Now, the QC20-W provides a full diagnostic of machine tools in one test—measuring roundness, verticality, and backlash. All data is stored in the Ballbar 20 software, giving engineers instant access, both online and offline. No more relying on memory. The Renishaw QC20-W has become the backbone of our quality system.”

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