Case Study
Recap: An automotive supplier was experiencing a complex and costly issue with its finishing department. The filter system was inefficient and required weekly replacement. OTC determined that using three different pocket filters to handle each stage of the finishing would quadruple the lifespan of the filters.
Our Challenge
Finding the source of inefficiency within an operation isn’t always easy. Many companies experience these inefficiencies and write them off as part of doing business. However, OTC Industrial Technologies is not satisfied with this approach and wants our clients to get the most value out of every aspect of their operations.
When a tier 1 automotive supplier came to us with a finishing problem that was costing them money and drastically reducing the life expectancy of their filters, OTC quickly got to work.
Inadequate equipment in its clear coat water RASH meant that the system was pulling in too much moisture. This affected the lifespan of the filters and potentially the quality of the finish. To manage the problem, the manufacturer was replacing the filters nearly every week.
Additionally, the high moisture levels contributed to machine efficiency losses due to spiking static pressure. While the system struggled to compensate, it was running inefficiently and costing the supplier more to operate. To make matters worse, replacing the filter meant the entire system had to be shut down, costing the supplier valuable production time. Unsure of the best path forward, they contacted OTC for help.
Our Solution
After learning about the problem, the OTC team went to work. Recognizing that the ineffective filters were the root cause of the issue, they reached out to three different trusted vendors for possible solutions. With a variety of strategies in development, they began testing each approach on-site.
Through rigorous testing and analysis, carefully setting up a test production environment to analyze possible filter solutions, OTC was able to determine that using three different pocket filters to handle each stage of the finishing would drastically increase the lifespan of the system.
If you have questions about any of the work done here or would like an analysis of your finishing system to identify cost savings and efficiency opportunities, then contact OTC today.
After implementing OTC's custom solution, the lifespan of the filters quadrupled.
Results
The new system is much better suited to the client’s needs. The new filter solution not only reduces the manufacturer's costs but increases efficiency and quality in production.
Before working with OTC, the automotive supplier replaced its filters each week. This meant constantly shutting down production to address this critical issue. After implementing OTC’s custom solution, the lifespan of the filters quadrupled. Now they last a month or longer. Additionally, the new filters reduced the strain on the rest of the system and allowed the machines to work more efficiently.