Product category:
Cutting lubricants, coolants, systems and treatment
News Release from: Castrol UK | Subject: Lubricants management service
Edited by the Manufacturingtalk Editorial
Team on 16 January 2006
Ongoing lubricants improvements saves
costs
In spite of higher energy costs and oil price increases, ongoing lubricant supply improvements have helped an automotive systems manufacturer maintain the same internal cost structure.
Following the success of a third regular review of its Coolant and Chemical Wash Management Contract with Albion Automotive, Castrol is celebrating being on site for ten years The name Albion can be traced back to 1899 when the company manufactured cars, but is probably best remembered as a manufacturer of buses and trucks
This article was originally published on Manufacturingtalk on 12 May 2006 at 8.00am (UK)
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More than a hundred years on, the company is still involved in the automotive industry, now as Albion Automotive - a wholly owned subsidiary of American Axle and Manufacturing (AAM).
AAM is a world leader in the manufacture, engineering, design and validation of driveline systems and related components and modules, chassis systems and metal formed products for light trucks, sport utility vehicles and passenger cars.
In addition to its locations in the United States (in Michigan, New York and Ohio), AAM also has offices or facilities in Brazil, China, England, Germany, India, Japan, Mexico, Scotland and South Korea.
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.
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.
At its headquarters in Scotstoun, Glasgow, Scotland, the company now predominantly specialises in the design and manufacture of front and rear axles for commercial vehicles, using state of the art 3D modelling and leading edge gear cutting and machining technology to manufacture 45,000 axles a year and various transmission type components.
With customers such as Paccar, LDV, Renault, Volvo and DaimlerChrysler the company's manufacturing facility is kept busy providing finish machined steel forgings and SG Iron castings, for sub-assembly and final assembly on-site.
Castrol has been on site for more than ten years following a strategic review of cutting and other process fluids.
Castrol was initially appointed to take responsibility for coolant management only, and this was then expanded to include chemical washes.
The company currently operates with a team consisting of contract manager Phil Coyle and three fluid technicians.
Castrol monitors fluids regularly for pH and bacteria levels, changes are scheduled, and from a health and safety perspective things have improved 100%.
Over the past 10 years the Castrol team has introduced a range of fluids for the Albion site.
Hysol X, a soluble coolant, is the main cutting fluid with some Syntilo XPS and Ilocut 486 neat oil also used.
It was four years ago that Castrol was given responsibility for fluid management in the site's component washing operations to ensure that fluids and the components themselves are maintained in peak condition.
The Castrol team now makes sure that wash fluids are clean and optimum chemical mixes maintained.
In addition, Castrol recommended a change to its Iloquench No 9 for the site's 8,000 litre capacity quenching tanks.
Contract management is reviewed at regular monthly meetings with the Castrol team.
The contract manager covers any issues he has, and reports on all activities and improvements carried out since the previous meeting.
Everything is documented and Albion receives a detailed monthly report.
In spite of higher energy costs and oil price increases, Castrol's improvements have helped Albion maintain the same internal cost structure, which represents significant cost avoidance in real terms.
The Castrol team manages all metalworking and component wash fluids and the all-inclusive contract is extremely convenient for Albion in various areas such as forecasting, flexibility and expertise.
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