Problem: An aviation manufacturer has multiple welders which are cooled by hydraulic oil. Some of the welders have dedicated oil filtration systems installed on them to remove water and contaminants from the oil. Periodically, they would have issues with the welders, filtration system and oil resulting in a loss of production. They also did not have quantitative or qualitative data on the oil itself. So they called us in to help them analyze their systems and develop a cost efficient maintenance program for them.
Solution: We first did a detailed survey of all of the filtration systems, filters used and filter change frequency and compared that survey to their internal documents. As expected, some inconsistencies were found and corrected. We inspected each filtration system for proper operation and then gathered oil samples and had them tested at a certified lab for particles, % water and viscosity.
The results of the oil analyses showed which systems had issues with the oil quality. We then made recommendations as to the type and frequency of the filters changes to minimize issues and extend the life of the oil. We also made recommendations for repairs or changes to the filtration equipment to increase their effectiveness. Using this systematic approach, we are helping them develop a focused maintenance program which will improve machine reliability and reduce downtime and fluid costs - potentially saving them hundreds of thousands of dollars.