$100,000 in Savings: How DR3704 Solved Our Measurement Errors

$100,000 in Lost Production: The Gauge That Lied by Staying Still

Our maintenance team faced a costly discrepancy. The hydraulic press was cycling slower than expected, and the analog gauge showed normal pressure. However, every formed part was out of spec. Initially, we assumed a mechanical fault, but the symptoms pointed to a measurement error. Therefore, we reviewed our SCADA trends. Unfortunately, the SCADA system reported steady pressure. As a result, we were scrapping batches and absorbing $100,000 in annual lost production and rework. The SCADA system showed no anomalies, so the failure was hidden in plain sight.

What SCADA Didn’t Reveal: The 80ms Pressure Spike

PLC scan rates are optimized for process trends, not millisecond events. Specifically, a 500ms scan rate means anything faster than half a second remains invisible. For instance, an 80ms pressure spike can occur and vanish between samples. This is classic aliasing: the digital system undersamples the physical signal. Therefore, the SCADA transient capture failed, and our pressure data logger was needed to see the true waveform. In fact, high-speed logging at 10ms intervals can reveal these brief disturbances. For more on transient capture, see Control Engineering.

How DR3704 Solved Our Hidden Pressure Spikes

We installed the DR3704 Digital Pressure Gauge with Data Logger. This digital pressure gauge with logging is purpose-built for high-precision logging and trend analysis. Its onboard logging at 10ms intervals captured every fluctuation in real time. Moreover, the SD card storage and CSV export let us analyze events in PC software. Consequently, we identified a series of brief pressure spikes that correlated directly with out-of-spec parts. Then we adjusted process parameters and optimized the press cycle. Also, the IP66 housing survived washdown and hydraulic mist.

Why Did a 15% Yield Gain Save Over $100,000?

Within one week, yield improved by 15%. As a result, we eliminated $100,000 in lost production and rework. Furthermore, the DR3704 paid for itself immediately. The pressure data logger also provided long-term recording for preventive maintenance. Therefore, we now catch transient faults before they become scrap. Notably, this digital pressure gauge with logging turned an invisible 80ms event into actionable data.

Key Specifications

• Built-in data logging for pressure trend analysis
• SD card storage, CSV file format export
• High accuracy measurement
• Battery-powered, 3-5 year battery life
• Protection class IP66
• Large memory capacity for long-term recording
• Data export for PC analysis

How many hidden transients are still slipping past your SCADA system? If your process runs faster than your scan rate, then a pressure data logger may reveal the cost. Consider the DR3704 for your next measurement audit.

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