Staylor concluded that the solution was to put a heat ex- changer on each coolant fi ltration unit and a cooling tower out- side. He designed and installed a system in which the oil from each machine runs into the heat exchanger and then back into the fi ltration unit, while propylene glycol comes into the heat exchanger and then back outside to the cooling tower. The cooling tower requires just a few hundred gallons of the propylene glycol, which is chemically inert and poses no risk to the environment. Staylor retained the existing chillers
in the fi ltration units to serve as back- ups and to augment the heat exchang- er system during periods of heavy material removal when a machine’s temperature may rise more than 2°. So the internal chillers don’t run much and when they do, it’s only on one machine at a time.
“The secret here is that we’ve cross-trained almost everyone to run everything and to design tools themselves.”
Sonic also invested in a variable- speed air conditioning unit. It runs with enough frequency to maintain circulation and comfortable humidity, but automati- cally adjusts its speed to what’s needed. The system also automatically intro- duces fresh air into the shop when the outside temperature is cooler. All told, the heat exchanger and air conditioning systems cost Sonic roughly $80,000 (not counting Staylor’s engineering time). Staylor said the sys- tem will pay for itself in electricity alone in about seven years. More importantly, he’s convinced it paid for itself in the fi rst year to 18 months by reducing the scrap rate to under 3% and by improv- ing morale during the summer.
The innovative drive concept of the Schutte 325linear combines highest precision with maximum dynamics.
Whether you produce instruments or implants, the 325linear brings exceptional productivity on the smallest footprint in the business.
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“The people who work here are more important than the people I work for,” he said. “They just are. Because if they’re too hot, they make crap. If they’re happy, they make great tools. So you concentrate on your staff.” But it’s not
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info@schutteusa.com
July 2015 |
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