Copyright 2008 ©

Metalworking Lubricant Services.

Initial Consultation

 

 

 

 

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.

 

 

Summary

 

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

 

By changing to MLS, the savings per annum would be

£138,200 per annum.