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

Pump manufacturers have not only managed to extend the lifespan of their machine tools, but also achieved a 10% reduction in unplanned downtime. The Renishaw QC20-W ballbar system is widely recognized as a powerful tool for preventive maintenance, both for 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 cut production and maintenance costs, boost output, and minimize waste.  As the manufacturing sector increasingly embraces Total Production Maintenance (TPM), Aquasub sought innovative solutions. Upon learning about the newly launched Renishaw QC20-W wireless ballbar system, they invited Renishaw for a product demonstration. The results were impressive—offering detailed data on various machine tool errors with high accuracy. The QC20-W can identify up to 18 different geometric and dynamic errors, providing more reliable diagnostics than previous methods. The successful demonstration of the QC20-W at Aquasub not only built trust but also convinced them that the system would become an essential part of their TPM program. **There are many benefits to using the QC20-W**  To avoid unnecessary purchases of new machine tools, Aquasub aims to maintain its existing fleet of 200 machines, most of which have been in operation for over 25 years. General Manager K Senthil 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 boosts efficiency and keeps the machines in good working condition. Our downtime has already dropped by 10%. By collecting detailed data on each machine, even small technical issues are quickly identified. We now perform three plane tests in one setup, cutting inspection time by 20%.” **Regular testing is critical** Mr. Kumar continued: “We store test data from each machine in the Ballbar 20 software. This helps us create a maintenance schedule and take action before quality issues arise. When machines are well-maintained, workpiece quality remains stable. Since integrating the QC20-W into our routine, we’ve seen a significant drop in waste and defects.” Even new machines are tested upon installation, as there is always a risk of damage during transportation or initial setup. **The right tool for the job** The Aqua Group offers a wide range of products used in critical applications such as agriculture, urban, and industrial water supply. With 4,000 pumps produced daily, the reliability of their 200 machines is crucial for meeting delivery commitments.  The group’s strategy focuses on continuous improvement through enhanced knowledge, technology development, and process optimization. Implementing a comprehensive maintenance program ensures consistent product quality and identifies areas for further growth. Mr. Kumar added: “Previously, we relied on engineers’ subjective assessments, which led to a high risk of human error. Now, the QC20-W provides a complete diagnostic of each machine in one test—measuring roundness, verticality, and backlash. All data is stored in the Ballbar 20 software, giving engineers instant access to historical performance records. We no longer depend on memory. The Renishaw QC20-W has become the backbone of our quality system.”

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