The cleaning of moulding tools at a brake linings and clutches production company is carried out in a traditional way in a caustic soda bath, a method that is not very efficient, and also generates very heavy liquid discharges. Switching to ultrasonic cleaning optimizes the cleaning operation, reduce the cleaning time, and provide better work conditions for the workers.
A brake linings and clutches production company has two impregnation booths. Thermal energy is provided by steam in the one booth and by electrical resistance in the other. As the electric resistance has higher efficiency, and maintains better control over temperature within the booth, the steam operated booth is converted to operate by electrical resistance.
An automotive cables manufacturing company had four large motors that are close to the end of their service life, and are direct current motors. Replacing those motors with asynchronous AC motors increases the motor efficiency, and reduces its running cost. This action also saves on electricity consumption of the company.
Stoppage of wire drawing machines generates losses in raw material. Investigating the reasons for these stoppages in an automotive cable company revealed that lack of machine maintenance together with the low quality of used copper are main reasons. adopting preventive maintenance program, and contacting the copper suppliers to provide high quality material reduces those stoppages, and consequently saves on material and increases productivity.
Iron oxides generated within the quenching process are lost as they are contaminated with oil from the quenching bath, and is drained from the bath as hazardous waste.
Installation of a centrifuge separator to recover the iron oxide reduces the hazardous waste, and allows the collection of the iron oxides to be sold for scrap traders.
In a surface treatment process, benchmarking the chromium losses highlighted that the company exceeds the common practice level of those losses. Modifications to the chrome plating bath, and the setup for parts rinsing, supported reduction of chromium loss.
The setup and structure of the powder coating boothes, being of steel strucutre and relying on manual process resulted in significant powder losses, and inconsistency of product quality. Changing the booths to plastic structure facilitates its cleanining between colors, led to improved product quality. Losses of the powder were reduced through changing the automation of the feed system.
Hooks, overwhich parts to be painted are hung, used to be cleaned (paint removal) using chemical methods that generate hazardous waste. Shifting to a pyrolysis process for paint removal reduced the chemical consumption, and associated hazardous waste. It also enhanced the productivity of the company, as the cleaning time was reduced.