The Problem: A Michigan wheel manufacturer was facing numerous problems associated with the quality and maintenance of their coolant and cleaners. These problems included downtime quality control rejections due to corrosion of parts, pumps clogging with biological matter, and operator complaints of coolant odors. Concurrently, the plant needed to reduce fluid-related costs and improve data collection and management for the industrial fluids used at their facility.
The SRS Service: SRS was contracted to provide this customer with a Fluid Control total fluid management program. The Fluid Control program at this facility consisted of responsibilities in purchasing; inventory control of all chemical used in the facility; waste water treatment; ISO certification; analysis and control of the in-process fluids; and data collection and storage.
Upon the startup of the program, SRS analyzed the in-process parameters for current coolants and cleaners. Over the first few months, SRS implemented improved strategies for fluid analysis and dilution control to stabilize in-process parameters. At the same time, SRS implemented a plant-wide fluid purification strategy using SRS proprietary fluid purification technologies to reduce and stabilize contamination levels.
- stabilized and improved in-process fluid parameters, improving environmental and health & safety impacts, reducing fluid waste, and saving money on fluid purchases.
- improved tool life by 30% plant-wide, saving directly on tool costs and reducing downtime for tool changes.
- significantly improved warehousing and distribution through the patented SRS iFluid Wizard™ data collection and management system
- shown a tremendous positive environmental impact, reducing waste water effluent by 78% on a daily basis.
Average metalworking fluid concentrations have been reduced from 9.7% to 5.5%, reducing fluid waste, improving air quality, and positively impacting worker health & safety. Average system pH’s have been increased from 8.8 to 9.2, improving fluid and biological stability. Both solid and oil contamination levels have been reduced by over 80%, improving fluid stability, extending sump life, and saving on filtration costs. Complaints of coolant odors and biological growth have been drastically reduced, as have the quality control rejections due to corrosion of parts.
Documented Cost Savings Produced………over $1,000,000.