Back To The Basics: Process Improvement Basics

We understand that it is more important than ever to realize savings within manufacturing processes. EXAIR can reduce compressed air consumption and provide simple ROI in a matter of weeks in MANY cases.

In the hustle and bustle of the daily grind wherever you are, there are certain processes that become muscle memory for you and certain processes that just work and don’t need any attention. Whether it be a login process for your computer network, the number of steps it takes to fill your coffee cup, or the compressed air applications in your facility.

You know what I am talking about, these items begin to get glanced over and often become overlooked. When going through process improvements or troubleshooting, it is easy to overlook processes which are not causing trouble or that have become “acceptable” because they are producing. EXAIR firmly believes compressed air applications are ripe for improvement, and our product lines are built to replace inefficient compressed air products with engineered and efficient solutions.

When evaluating a process for improvement creating a baseline is the necessary start. With this, we can then start to draw a realistic target of where the process needs to be in order to be optimized and document the changes from our starting baseline.

Much like the 6 Steps to Compressed Air Optimization, which starts with measuring compressed air consumption to provide a baseline.  Sometimes, this may require the installation of a Digital Flowmeter, others it may include taking advantage of our Efficiency Lab service for us to get a baseline of what air consumption and other key performance indicators are for your application.

Looking to “go green?” We can help.

Once we have the baseline and a target, we can then begin to design an improvement process. Whether this is implementing better controls for the air, such as pressure regulators, or implementing controllers such as the Electronic Flow Control, it may even be simply installing an engineered solution.  Once an improvement has been implemented we can then go on to the next testing phase to again gather data to see how much air was saved from the baseline.

EXAIR’s Free Efficiency Lab

Once the performance of the new process is determined then we can take the new cost of ownership numbers and give a simple return on investment back to determine what the actual savings by implementing these process improvements have amounted to.

The below example is from a customer who had already improved their static elimination application by using our Super Ion Air Knife instead of a homemade pipe with drilled holes. They further optimized the application with our Electronic Flow Control.

If you would like to talk through methods for process improvement or how we can help you determine these costs, please reach out.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Prepping For The Heat. (Not Solar Flares)

Well, the first day of Spring is right around the corner.  It’s hard to believe that the Summer heat isn’t that far out for us here in Cincinnati.  Of course the first thing on my mind is hanging out outside with my daughters, and track days.  What isn’t on my mind is the heat that most production environments feel.  It most likely isn’t on your mind either, and won’t be until the heat is here and the machine is shutting down.

High Temp Cabinet Cooler

Why not be proactive and fill out a Cabinet Cooler Sizing Guide so that we can help to prevent that down time in the Summer months?  Even though the temperatures aren’t as hot as they will be in a few months, the temperature differential will still allow us to calculate the heat load that is generated within the enclosure.

Sizing Guide

There’s no better time than now to start preventative measures to keeping your machines running.  Whether that is by installing a thermostat controlled Cabinet Cooler System, using a Chip Trapper to filter coolants or a Cold Gun Aircoolant System to keep a cutting tool cool.  All methods will help you to keep production up and lessen the down time and the costly replacements of your equipment.

If you have any questions on how we can help, feel free to contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF