Overview
A Tier 1 automotive supplier encountered persistent complications with its filtration setup. The existing system failed to align with strict airflow requirements, resulting in frequent filter replacements, rising costs, and periodic disruptions to production.
- Customer: Automotive Manufacturer
- Relationship with OTC: 30 years
Challenge
The automotive supplier’s finishing department relied on a consistent and reliable airflow to maintain product quality while painting critical automotive components. However, their supplier’s filters were installed improperly within the paint system which inhibited the airflow parameters the manufacturer required. This incorrect application led to unplanned shutdowns and lost production time. Technicians were forced to replace these suboptimal filters every one to two weeks due to the unreliability allowing water, solvents, and sludge in during the painting process.
As the painting lines faltered, the company found it increasingly difficult to meet delivery schedules and maintain adequate inventory. Recognizing the severe operational impact, the supplier sought a more effective strategy.
Solution
Already providing weekly technical support to the paint division, OTC Industrial Technologies was well-positioned to evaluate the root causes behind the filter failures. Their experts observed that the filters not only underperformed in the face of airflow constraints but were also mismatched to the supplier’s specific finishing processes.
OTC created a tailored solution that optimized filtration efficiency without necessitating extensive capital investments in new equipment.
- Analyze the System and Collaborate with Vendors - OTC first conducted a comprehensive review of the finishing process to identify specific airflow and contamination requirements. After uncovering design inefficiencies, OTC collaborated with three specialized filter vendors. Each vendor’s solution was tested on-site to evaluate performance under real-world operating conditions, ensuring the most effective and reliable filtration system was selected.
- Create a Custom Filter Configuration - Drawing on the insights gathered from the analysis, OTC and its partners selected three distinct pocket filters to address each stage of the paint finishing process. This layered approach enabled more precise filtration, ensuring filters aligned seamlessly with the department’s airflow demands.
- Material Replacement and Installation - The custom-designed filters were installed to replace the previously misapplied system. By optimizing both the filter type and placement strategy, the new setup significantly enhanced airflow stability while reducing premature blockages.
Results
Transitioning to OTC’s tailored filtration solution delivered immediate and substantial benefits. Most notably, OTC’s solution quadrupled the usable lifespan of the filters, drastically reducing the frequency of replacements and associated costs.
By minimizing the need for frequent filter swaps, system shutdowns became markedly less frequent, enabling more continuous production and improved output. With fewer disruptions to the finishing line, the automotive supplier’s personnel could devote more time to high-value tasks rather than maintenance, contributing to better overall productivity and faster delivery times.
In addition, because the new filters require fewer replacements and put less strain on machinery, the supplier has observed a reduction in carbon usage and an increase in energy efficiency.
Ultimately, the enhanced filtration system enabled this Tier 1 supplier to maintain a consistent production workflow, meet demand more reliably, and lower its total cost for filtration operations and maintenance. By partnering with OTC, the supplier achieved a resilient, reliable infrastructure better suited for the application.
Learn more about how OTC’s filtration experts can improve operations and drive efficiency.
