Recommendations for improvements
Implementation plans and support
Root Cause Analysis
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Tool changers on a transmission test stand were faulting due to an unknown, sticky contaminant residue. Oakland Chemical assisted in the tear-down and inspection of the spindles, took samples, and performed chemical analysis to identify the root cause. Oil incompatibility from an upstream operation was identified and assistance was given to select proper oil for that application. Downtime was eliminated due to that cause.
Severe, but sporadic pitting on polished cyclinder rods post nitride heat treatment was causing high scrap rates. The coolant being used in the upstream polishing process was being blamed. Oakland Chemical was commissioned to determine if this was the cause and if not, what was the root cause and suggest fixes. Samples were obtained and analyzed. It was determined the atmosphere on the furnace could be the root cause. After a seal replacement on the furnace the problem was resolved which eliminated the scrap from his cause. It wasn't the coolant after all.
A glass-like deposit was forming inside a furnace leading to increased scrap rates and premature failure of the furnace. Oakland Chemical was commissioned to determine the root cause and suggest solutions to eliminate this problem. Onsite investigation was performed, samples taken, process evaluated, and laboratory analysis performed.
The root cause was determined to be from an improper curing an upstream boron based carburizing stop-off heat treatment. The process was evaluated and a short and long term solution was implemented.
By reproducing the failure mode, it was determined that the incumbent coolant was not adequately protecting the machines. Oakland Chemical lead a project to find the best product for this application. A team was formed that included managers, engineers, union members, and operators. KPIs were identified, (both in the laboratory and on the plant floor), and testing completed.
By using data to select the right product and communicating properly, not only was the rust inside the machines eliminated, other improvements include residue reduction keeping machines clean, tool life improved, and recycling enabled. The result was improved up time, worker acceptance, and production rate improvements.
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Oakland Chemical can help you to drive down costs and improve productivity.
Oakland Chemical strives to provide World Class Support to our business partners through Technical Expertise, Training, and Laboratory Analysis, leading to Root Cause Determinations and Solutions that will positively impact Safety, Cost, and Quality. All aspects of Oakland Chemicals operations will be done with the mindset of Safety First, for both Oakland Chemical and our Business Partners, as well as having a positive impact on the Environment.
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