A world class manufacturer in India. They manufacture 2 wheelers and 3 wheelers wide range of products.
Application : Aluminum machining
Process : Machining, Drilling, Tapping, Boring
No of machine : 80 No’s
Fluid : Water based emulsion
Multiple part of a 2 wheeler are made of aluminum die cast. Components are machines, drilled and bored to achieve finished stage. This generates large quantum of chips. Considering the high production requirements multiple machines are working at the same time.
This generates a large quantum of chips. Chips were separated in individual tanks and fluid pumped back to machine. Chips had to be cleaned manually from each tank. This caused significant machine downtime. Customer wanted to reduce this machine down time and if possible completely eliminate it.
Properties of coolant like pH, concentration etc. had to be maintained at each machine. This caused irregularities and required lot of manpower.
Due to the space limitation available for individual tanks, filtration level achieved was compromised resulting improper filtration reducing the coolant life and frequent breakdown of machines.
Customer wanted to explore the possibility of adding additional machine in the same shop floor to match the ever increasing production demand
Veeraja proposed a centralized filtration system with large conveyors and mesh drum filters. A layout was prepared with the process planners from Bajaj Auto ltd. Civil trenches were dug in existing machine shop. Advance in civil engineering has made it possible to dig inside the shop floor without disturbing adjacent machines.
Careful coordination with various agencies and technical team Bajaj Auto Ltd ensured that production is hampered the least. A large pit to accommodate a 15000 LPM central filtration which total tank capacity of more than 1,00,000 liters was constructed outside the shop. U shape gutters were fitted in the trenches and a central filtration was installed in the pit. A regularly tracked project execution ensured on time delivery and smooth transition from individual to Centralized filtration system
Individual tanks were removed and dirty fluid outlets of all machines were connected to the U shaped gutters. These carry the fluid and chips to the CFS. Sufficient gradient ensured all is transferred without any blockage and accumulation. Additional flushing nozzles tapped from high pressure supply line are used at regular intervals.
- Coolant life increased from 3 months to 3 years.
- New machines were added due to the space saved by removing individual tanks.
- Manpower was reduced.
- Lesser breakdown and downtime of machines increased production capacities.
- Power consumption was reduced by 50%
