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Example of Initial Consultation Report of Metalworking Fluid Practices
MLS’ consultant engineers determine the cost benefits applicable to any given manufacturer through a carefully detailed consultation report. This report analysis’ the relative efficiency of the site and allows MLS to determine the scope of improvements applicable and the cost benefits of converting to a fixed cost agreement spread over 12 months.
Below is an example of the initial report generated at a major blue-chip automotive manufacturer based in the UK.
General Observations: -
- Annual usage of coolant approx. 80,000 litres
- Approx 40 machines on site
- Average sump capacity 1,500 litres
- Operating concentration 4 – 6%
- Many machines being emptied and refilled once a month to control corrosion
Comments: -
- Coolant concentrate consumption due to fluid changes estimated to be at least 24,000 litres per annum, 30% of total usage.
- We estimate with the correct fluid selection and management the amount of fluid changes can be reduced to a maximum one fluid change per machine per annum.
- Saving at least 21,000 litres of coolant concentrate per annum.
- Further significant savings can be made by eliminating the use of biocides, pH buffers and fungicides.
Productivity
Observations: -
- Coolant sumps are regularly emptied and refilled to prevent corrosion. We estimate that this occurs at least 20 times per month.
- Production cost per machine change is £70 / hour
- Average time to change machine coolant 4 hours
Comments: -
- Average 6 coolant changes per machine per annum
- Resulting in 240 machine changes per annum
- Lost productivity 240 x 4 hours = 960 hours x £70 = £67,200 per annum
- We estimate with the correct fluid selection and management the amount of fluid changes can be reduced to a maximum one fluid change per machine per annum. This change could be planned during a shutdown period resulting in no loss of productivity,
- Saving 960 hours of machine available time at £67,200 per annum.
- Corrosion problems would be eliminated.
Waste Disposal
Observations: -
- Waste fluid produced, 1,866,000 litres, we estimate that 80% of this waste is coolant, 20% wash chemical.
- Estimated cost to remove waste £72,000 per annum
Comments: -
- We estimate with the correct fluid selection and management the amount of waste can be reduced by 90%.
- The remaining 10% can be processed on site at a one off capital equipment cost of £10,000, and a maintenance cost of approx. £1,000 per annum.
- Potential savings of £62,000 per annum in year one, £71,000 per annum thereafter.
Health & Safety
Observations: -
- Sticky deposits leading to poor machine tool cleanliness
- Regular bad odours due to bacteria
- Regular additions of biocides
Comments: -
- The sticky deposits are the result of the coolant breaking down due to bacterial infection; these infections and deposits can be easily eliminated.
- Routine dosing of single sump CNC machines is considered bad practice by the Health & Safety Executive.
|
Description |
Current Cost |
Potential Cost |
|
Waste Disposal |
£72,000 |
£1,000 |
|
Product Consumption |
£112,000 |
£112,000 |
|
Lost Productivity |
£67,200 |
£0 |
|
TOTAL COST |
£252,200 |
£113,000 |