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Hermes Abrasives Avg. Unit Cost |
$.0172 |
|
Uneeda Enterprizes Unit Cost |
$.0073 |
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UNIT COST SAVINGS TO DATE |
57.56% |
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Products and Solutions featured in this case study
For whitewood sanding, Ekamant uses an Aluminum Oxide grain that is “FRIABLE”. This means that our Aluminum Oxide grains re-sharpen when they fracture. Once the grain fractures, new sharp grains are exposed. Competing brands use standard Aluminum Oxide grains that dull after the initial, sharp tip is broken. The grains then continue to dull as they fracture and wear.
This dulling of the grain requires the end-user to use much more pressure on competing brands of sandpaper to accomplish the same cut as they achieve with our grains under light pressure. This can cause many problems to include:
Consistent Grain Height
Competition’s Grain is not uniform in Height – Results in an Uneven Scratch Pattern
New sharp edges are formed
Edges get dull
To get the best possible belt life and quality finish, it is imperative that each component of the machine is set to the correct heights and leveled. It is also critical for the sanding drums and platens to be level and removing the correct amount of material per grit used. We conducted preliminary testing. At that time, we found many of the components of the wide belt machines to be out of level.
Tony Bentley, one of our factory technicians, made several adjustments to the machine. Those adjustments were recorded. On the next page is a copy of the chart we use to record the adjustments made. These are the actual adjustments Tony made to the (4) head door face sander during our testing in January to show you an example.
In addition to the adjustments Tony made, a representative from SCM also worked on the machine between the time we tested in January and the testing we have engaged in over the last month. A new program implemented by ABC Co. further helps to ensure the machine stays in top operational condition. The maintenance department is now charged with the task of checking the machine heads on a regularly scheduled basis.
Keeping the machine in the best working condition is an ongoing effort. A perfect example of this occurred during the test. For the first (2) weeks of the test, we did not need to make any major adjustments to the machine. However, on the first day of the third week of testing, we quickly blew 5 belts, most on the second head of the door back sander. We were struggling to run good parts on that machine. At that point, the plant manager authorized stopping production to give Tony Bentley time to go through the machine with his digital indicators to check each sanding head.
When the indicators were put in the machine, we found the second head to be .020” too low. When trying to move the second head back into position, Tony noticed the readings on his indicators were not moving as he adjusted the head. In troubleshooting that problem, it was discovered that the set screw designed to hold the knob in position was stripped. Therefore, the Knob was simply spinning when adjusted and not actually moving the head into position. That was quickly fixed by the maintenance department. Tony was then able to make the appropriate adjustments. The machine ran great the following (2) weeks. The whole process of getting the heads back in the right position and removing the correct amount of stock only took about 25 minutes. No more belts were lost the rest of the first shift.
Another factor that has helped with the success of this trial was a process change in the type of belt material that was being used on the first head of both wide belt machines. You have traditionally run # 80 grit cloth belts. We did some experimentation the first day of testing and found that # 80 grit paper was the more appropriate choice to run on the first head. The paper belt is running much cooler than the # 80 grit cloth. Cloth by nature generates a lot more heat as the belts tend to have some polyester in the backing.
This heat increases the likelihood of burning which was one of your largest causes of belt changes. The life of the # 80 grit paper belts has been phenomenal. Most of the # 80 grit paper belts that had to be changed, were changed due to a water problem in the air lines not due to wear or any other problem. The water problem mainly occurs between shift changes and on night shift. Having a larger reservoir to catch the water or placing a dryer on the air lines will pretty much eliminate this as a problem. Once that is rectified, you should see very few belt changes on the # 80 grit paper.
A second process change implemented by ABC Co. that should also be noted is the addition of the roller to the front of the first machine to ensure only the correct sized parts are fed into the machine. This helps reduce the possibility of burning due to excessive part thickness and also helps ensure the machine components remain level for longer periods of time. The table that replaced the roller is even better. The only improvement we would suggest on the table would be to have rollers installed on the bottom of the table to make it a bit easier to feed the parts into the machine.
A very important factor in the success we have seen during this month long test is due to the great teamwork and cooperation that has occurred between the Uneeda and ABC personnel. It has really been a group effort.
The plant manager gave us an open door to do anything we felt needed to be done with regard to materials used, machine adjustments, etc. Without this freedom, we would never have seen the results we have. His philosophy of stopping production to fix a problem rather than to continue fighting a problem while trying to run production paid dividends as well. It is always better to stop and fix a problem at its source, rather than to put a band aid on it for the sake of continuing the production flow. In most cases, we find that stopping production to fix the problem when it arises is a great savings compared to fighting machinery to produce good parts.
A second process change implemented by ABC Co. that should also be noted is the addition of the roller to the front of the first machine to ensure only the correct sized parts are fed into the machine. This helps reduce the possibility of burning due to excessive part thickness and also helps ensure the machine components remain level for longer periods of time. The table that replaced the roller is even better. The only improvement we would suggest on the table would be to have rollers installed on the bottom of the table to make it a bit easier to feed the parts into the machine.
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We are certain there are more cost savings to be found and look forward to working with you to further improve processes that will show positive results on your overall cost to manufacture.
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Is a revolutionary product suited for the sanding of all hard and soft woods. Utilizing Ekamant’s 3rd generation of anti-static technology, EKA1000 achieves a superior quality finish with excellent abrasive life.
EKA1000 is extremely durable and can withstand even the harshest application while still leaving a uniform scratch pattern. Suited for wide and narrow belt sanding, EKA1000 will help reduce manufacturing costs significantly.
We also want to be clear that the support Uneeda has given ABC during this trial period will be continuous. We do suggest that ABC purchase a set of indicators. We would work with your maintenance department to train them on their use. This will greatly reduce set up time when work on the wide belt machines must be done.
