Product category:
Cutting lubricants, coolants, systems and treatment
News Release from: Castrol UK | Subject: Total fluid management programme
Edited by the Manufacturingtalk Editorial
Team on 04 December 2002
Total fluid management saved production
costs
When TRW Automotive began losing production time due to fungal problems in machine tools, they decided to take on a total fluid management programme and saved some GBP 150,000 in 3 years.
When TRW Automotive began losing production time due to fungal problems in machine tools, they decided to extend their long-term relationship with Castrol to include the Castrol total fluid management programme The decision proved to be the right one
This article was originally published on Manufacturingtalk on 6 Feb 2004 at 8.00am (UK)
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Castrol has produced savings equivalent to GBP 150,000 in the first three years and, in addition to environmental benefits, machine downtime due to fungal problems has been reduced to zero.
TRW Automotive, a major manufacturer of light vehicle braking systems, is based in Pontypool, South Wales and has enjoyed a traditional supply-only relationship with Castrol for more than twenty years.
Bill Jones TRW technical support manager explains the reasons for the move to Castrol total fluid management.
Further reading
Coolant trials lead to significant annual savings
Offering a One-Stop-Shop engineering service that includes casting, machining and paint finishing, a Sandy company has saved more than 50% on coolant consumption - an annual saving of GBP18,000.
Overheats on automatics led to coolant change
Running two new sliding-head CNC machines at speed with a conventional chlorine-free mineral oil caused serious overheating problems until the user changed to a synthetic cutting fluid.
"Whilst the fungal problems were our main concern we also had an ad hoc machine cleaning programme, didn't have accurate coolant usage figures and our waste disposal costs were escalating.
" "Introducing Castrol total fluid management has helped us gain control of our coolant management, improved the working environment and significantly reduced costs." The Castrol contract covers 126 machines running processes such as Mapal bore reamings, transfer and CNC machining lines and general machining.
It includes stock management, fluid condition monitoring, product distribution, application cleaning and metalworking fluid waste disposal.
To manage and continuously improve the programme, Castrol provide a contract manager and two fluid technicians supported by coolant recycling units, distribution equipment, and computerised maintenance management systems.
The products supplied include Castrol Ilocut 106 and Castrol Ilocut 460AM neat oils and special soluble fluids such as Castrol Hysol G100, which was introduced to improve tool life and machine cleanliness and for its ability to reject tramp oil and improve recycling capabilities.
Bill Jones says important benefits gained by the move to total fluid management have included targeting cost saving initiatives that support TRW's internal 'Opportunities For Improvement' (OFI) programme and the machine shop's increased ability to focus on its core function.
"We also estimate that, by eradicating fungal infections, reducing scrap rates and waste disposal costs, rationalising coolant usage and recycling soluble fluids, Castrol has saved us GBP 150,000 in three years." So impressed are TRW that Bill Jones is considering adding lube management and first line filter changes to the contract.
"Our experience with fluid management has convinced us that handing over servicing and maintenance responsibility to Castrol will extend gearbox, spindle and bearing life and improve reliability and efficiency" Through this established programme with supporting documentation, Castrol has also been able to support TRW's ISO 14001 Accreditation.
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