Application
High Severity Machining Operations
Challenge
A Tier-2 Automotive Company in Ontario, Canada had been utilizing an incumbent coolant across its high severity machining operations. While effective, their process incurred high costs per liter and required frequent change outs due to poor coolant stability, leading to increased operational expenses and reduced technician availability. To address these challenges, the FUCHS Smart Services team developed a comprehensive solution that combined our high-performance ECOCOOL coolant with industry-leading monitoring and maintenance, while ensuring that tool life and operational metrics were not negatively impacted.
Solution
Two spinner machines were selected for the trial due to the high severity of the machining operations as well as the tight tolerances required. A trial protocol was developed measuring baseline concentration and consumption data. The FUCHS Smart Services team supervised the conversion of two machines prioritizing safety and minimizing operational interruption. Over a 3-month period, stringent FUCHS Smart Services monitoring and maintenance protocols were implemented, meticulously tracking all coolant parameters ensuring a stable coolant condition and efficient utilization.
Results
At the conclusion of the trial, the results demonstrated a clear advantage to implementing a FUCHS Smart Services solution.
Machine #1:
- Coolant consumption reduced from 50.6L to 19.1L (≈62% reduction).
- Costs dropped by 76%, delivering $391 trial savings and projected $5,608 annual savings.
Machine #2:
- Coolant consumption reduced from 54.2L to 21.6L (≈60% reduction).
- Costs dropped by 75%, with projected $5,321 annual savings.
The comprehensive solutions package delivered by FUCHS Smart Services proved to be more stable and required less frequent maintenance compared to the previous process. This enabled technicians to allocate their time to critical tasks such as planning and production work, improving overall productivity.
Additionally, the transition was smooth and no reduction to tool life was observed throughout the trial process. Beyond direct cost reductions, the organization benefits from reduced ordering frequency, improved technician productivity, and enhanced operational efficiency.
FUCHS Smart Services solutions contribute to lower total cost of ownership and the support long-term strategic goals of any customer.
Advantages
- Improved Coolant Stability & Efficiency
- Enhanced Productivity Without Compromise
- Reduced Total Cost of Ownership