Continuous Improvement





Following are examples of companies whom we've been able to optimze their processes while realizing significant cost savings:

Cummins – Paint Pretreatment & Powder Coating
Operations

Situation:

Cummins is a global leader in the design, manufacture, distribution and service of engines and related technologies, including fuel systems, controls, air handling, filtration, emission solutions and electrical power generation systems. They wanted help at their Black River Falls, WI location to make continuous improvements in the paint pretreatment and powder coating operations. Like most factories, they get utility bills for the entire complex but did not have detailed data collection capabilities to show them daily use of natural gas and electricity by operation.

Process Improvements:

Profit Finders implemented a data collection and analysis program to capture DAILY information in the paint pretreatment and powder coating operation for:

  • Natural Gas
  • Electricity
  • Chemicals
  • Water

Benefits Delivered:

Analyzing base line data and implementing continuous improvement changes have provide the following benefits:

30% reduction in natural gas consumption

10% reduction in chemical consumption

 


 

Tenaris – Tube Mill Operations

Situation:

Tenaris is the leading global manufacturer and supplier of tubular products and services used in the drilling, completion and production of oil and gas and a leading supplier of tubular products and services used in process and power plants and in specialized industrial and automotive applications. They are committed to continuous improvement and wanted detailed tube mill production data to drive cost reduction and productivity improvements. Also, they wanted to free up production labor from monitoring coolant so they could focus on producing tube.

Process Improvements:

Profit Finders implemented a data collection and analysis program to capture 24/7 data in all tube mills for coolant concentration, pH, conductivity, and temperature. This information allowed us to migrate to a “steady state” level of operation that is ideal for production efficiencies. Technology was also designed to capture daily usage data of coolant and water.

Benefits Delivered:

By analyzing base line data and implementing continuous improvement changes the following benefits have been realized:

27% reduction in coolant consumption

90% reduction in labor required to manage coolant sumps

 


 

 

General Electric – Critical Quality Paint Pretreatment
Operations

Situation:

GE - Transportation is a global technology leader and supplier to the railroad, marine, drilling, wind, and mining industries. GE provides freight and passenger locomotives, railway signaling and communications systems, information technology solutions, marine engines, motorized drive systems for mining trucks and drills, high-quality replacement parts and value added services. At Erie, PA World Headquarters GE manufactures locomotives, which involves critical chemical pretreatment operations prior to painting. They were using manual control methods for this operation and wanted to upgrade to a more sophisticated monitoring and control system.

How Embedded Sensors Were Used:

Profit Finders implemented a data collection and analysis program to capture 24/7 data in the paint pretreatment operations for concentration, pH, conductivity, and temperature. Technology was also designed to capture daily usage data for chemicals and water. Our technology was used to monitor and control the cleaner concentration automatically using time proportional control analysis.

Benefits Delivered:

More bottom line profits. With the use of the Profit Finders’ proprietary Embedded Sensors® technology GE has improved cleaning performance and:

Virtually eliminated quality defects

Reduced chemical use per locomotive by 34%

 


 

Arcelor Mittal – Hot Dip Galvanizing & Wastewater
Operations

Situation:

Arcelor Mittal is the world's number one steel company and the leader in all major global markets, including automotive, construction, household appliances and packaging. They wanted help at their Cleveland, OH location to make continuous improvements in their hot dip galvanizing line and overall wastewater treatments operations.

Process Improvements:

Profit Finders implemented programs for data collection and analysis to capture information on concentration, conductivity, temperature, and pH in cleaning tanks, rinse tanks, and the waste sump.

Benefits Delivered:

By analyzing base line data and implementing continuous improvement changes the following benefits have been realized:

15% reduction in cleaner consumption

Over $100,000 per year reduction in waste treatment costs


Call Us 216-476-8400 to find out more information.

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Chemical Methods, Inc. 20338 Progress Drive Cleveland, OH 44149 Phone: 216-476-8400 Fax: 216-476-1231

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Chemical Methods, Inc. is a leading supplier of custom industrial chemicals including aqueous cleaners, surface treatments,
metalworking fluids, laser oxide scale removal, corrosion inhibitors and water treatment chemicals.