Focus: GREAsE suPPLY. AuToMoTIVE GEAR AND AXLE coMPoNENT MANuFAcTuRINGPRoDucT suPPLY LEAD TIME cuT FRoM 6-8 WEEKs To 3 DAYs. No ENVIRoNMENTAL PRoTEcTIoN AGENcY REGuLATED HEAVY METALs IN REPLAcEMENT GREAsE. ANNuAL cosT sAVINGs oF usD $9,555.

cAsE sTuDY YouR ADVANTAGE IN AN INDusTRIAL WoRLD

THE cHALLENGEANALYsIsAND soLuTIoN

A manufacturer of automotive gear and axle components was having problems sourcing a grease for their FANUC robot axis reduction drives which was coming from Japan. Delivery lead times were up to 8 weeks, making it difficult to follow OEM recommendations on grease types and grease intervals. The manufacturer could not be sure that their machinery was running at optimal performance. They needed to save both lead time and cost of product.

• Product specified by the OEM and operating performance of the Castrol

product were both studied in detail to identify a suitable conversion.

• Castrol Optimol Longtime PDO grease was identified as an excellent replacement for the product the customer had been using and other greases for plant robots.

• Castrol Optimol Longtime PDO was shown to have the added advantage that it contained no barium.

ouTcoME• Lead times for product supply slashed from

6-8 weeks to just 3 days.

• Achieved a cost saving of USD $9,555 per annum at a usage rate of 35 pails per annum.

• Product performance is excellent for lubrication of axis drives and recommended a 3 year relubrication preventive maintenance programme.

PRoDucT suPPLY LEAD TIME cuT FRoM 6-8 WEEKs To 3 DAYs. No ENVIRoNMENTAL PRoTEcTIoN AGENcY REGuLATED HEAVY METALs IN REPLAcEMENT GREAsE. ANNuAL cosT sAVINGs oF usD $9,555.

cAsE sTuDY YouR ADVANTAGE IN AN INDusTRIAL WoRLD

www.castrol.com/industrialCastrol, the Castrol logo and Castrol Optimol are trademarks of Castrol Limited, used under licence.

Focus: GEAR AND AXLE. REDucE cooLANT cosTs IN cENTRAL sYsTEMGREATLY REDucED cosTs oF cooLANT usAGE, WAsTE TREATMENT AND ADDITIVEs. suRFAcE FINIsH EQuAL oR BETTER, EVEN IN DIFFIcuLT oPERATIoNs. FoAMING AND RAPID cYcLE TIMEs ELIMINATED. ToTAL sAVINGs oF usD $110,000.

cAsE sTuDY YouR ADVANTAGE IN AN INDusTRIAL WoRLD

THE cHALLENGEANALYsIsAND soLuTIoN

Coolant operations of System 63, an 88,000 gallon central system feeding multiple Turmat machining centres that produce automotive rack and pinion gear housings (383 aluminium) were proving costly. Coolant concentrate usages were very high along with additives to control foam, pH and bacteria. Foaming over was a usual occurrence along with rapid filter indexing.

Castrol undertook a careful, systematic analysis of the customer’s processes. A plan was produced to evaluate products according to a ranking system, based on a range of criteria spanning operator perception and actual performance and usage data. Based on the conclusions from the process analysis Castrol Alusol XT was charged to the system in 2002. Reverse osmosis water was implemented soon after to help extend coolant life. Strict controls were put in place to maintain quality of operations and ensure the coolant performed as expected. The coolant has been running successfully ever since the conversion.

ouTcoMEBefore Castrol Alusol XTConcentration – 8%Biocide additives – 510 gallon per annumCentrifuge costs – USD $4,000 per monthWaste gallons – 819,324 per annum

After Castrol Alusol XTConcentration – 10%Biocide additives – 0 gallon per annumCentrifuge costs – USD $0 per monthWaste gallons – 0 per annum

As a direct result of switching to Castrol Alusol XT, costs were greatly reduced in all areas: coolant usage, waste treatment, additives. Surface finish of manufactured parts was equal or better than the previous fluid, even in the most difficult operations of reaming the piston bore and valve bore (<31 RA requirement). Frequent foaming and rapid filter cycle times were eliminated. Total overall savings are in excess of USD $100,000.

GREATLY REDucED cosTs oF cooLANT usAGE, WAsTE TREATMENT AND ADDITIVEs. suRFAcE FINIsH EQuAL oR BETTER, EVEN IN DIFFIcuLT oPERATIoNs. FoAMING AND RAPID cYcLE TIMEs ELIMINATED. ToTAL sAVINGs oF usD $110,000.

cAsE sTuDY YouR ADVANTAGE IN AN INDusTRIAL WoRLD

www.castrol.com/industrialCastrol, the Castrol logo and Castrol Alusol are trademarks of Castrol Limited, used under licence.