Working together to increase profit through productivity

Productivity Consultancy

Cutting fluid productivity – a question of attitude from supplier and customer

There is never a wrong time to look at improving productivity and while typical targets for these gains are replacing older machine tools or, improving cutting tool technology. Jemtech can prove that cutting fluids play a major role in improving bottom line figures through its free of charge evaluation of your cutting fluid usage.

Examine A small percentage improvement in productivity can have dramatic effects on profitability, delivering a whole raft of other benefits for companies. However, while many companies instigate productivity improvements, few capitalise on all of the available aspects of the process. Taking advantage of most but not all available options can restrict the overall result.

By overlooking the effect that the correct choice of cutting fluid can have on a process, any gains made can be squandered. Correctly managed and properly selected, cutting fluid will deliver significant payback, in the form of increased cutting data, improved tolerance holding, improved surface finishes and increased uptime.

Cost benefit:

When investigating cutting fluids it is important to look at the true cost, not simply the cost per litre for concentrate. The total cost of use for cutting fluids is made up of several diverse elements, first we have the initial cost; top-up costs; cutting tool life; indirect costs (machine damage, health & safety issues, etc); maintenance costs; and of growing importance, disposal costs. The actual cost per litre to buy fluids is a very small percentage of the overall cost.

The first step in gaining an advantage from your cutting fluids is to take a close look at your monitoring and usage. Jemtech will help you review the following to deliver productivity gains:

  • Tool life
  • Cutting data
  • Surface finish
  • Tolerances
  • number of sump changes per year
  • Costs
  • Overheads ( hourly rate and down time)

This will highlight obvious improvement targets to drive the change through. By reducing waste, lowering product consumption; increasing machine uptime; improving cutting tool life and reducing labour costs, the benefits will be seen almost immediately.

Gains to be made:

A customer in the automotive sector, machining cast iron components, increased tool life by 200 per cent by switching to Blasocut BC25 fluid, generating tool cost savings of £275/week on one cutter alone (or £16,000 per year). Similarly, considerable savings can be made through good management of cutting fluids. If the cutting fluid is not suitable, or the concentrations are incorrect, or it is poorly managed (for example not removing tramp oil regularly), then sump life will be shortened considerably.

By using Blasocut BC20 at a sump concentration of between 7 – 8% and a top up of 1-2 %, considerably lower than the previous top up levels of 4–5 %, complimented with the installation of Fe-Ol tramp oil removing devices, the sump life was increased from two weeks to 26 weeks. This generated the following benefits:

  • 76 per cent reduction in fluid consumption
  • 23 per cent reduction in costs
  • Greatly reduced labour cost for cleaning out the sumps.
  • Considerably safer working environment for the operators.
  • Reduced waste disposal costs

Jemtech works in partnership with its customers to focus on producing components faster, longer, and better and not necessarily for the lowest initial cost.

By faster it means:

  • Higher feedrates
  • Increased depth of cut
  • Reduced secondary operations
  • Reduced cycle times and higher throughput.

Longer translates to:

  • Improved tool life
  • Reduced set-up times
  • Less machine downtime
  • Improved labour usage
  • Better return on investment.

In combining these elements Jemtech and Blaser have created the Liquid Tool, which means improved productivity through growth and prosperity, and an overall improvement in the manufacturing process.

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