Welding Line Gearbox

Welding Line Gearbox

Potential Cost Savings on all Welding Gearboxes on all Lines: $5263.49 x 48 = $252,­647.5­2 Per Annum

Interflon Grease MP00


Initial situation

The gearboxes are located on a radiator welding line; they are used to drive automatic welding heads welding both long & cross seams top & bottom of pressed radiators.

The previously used conventional lubrication product BP LITHIUM 2 GREASE was escaping from gearbox seals, contaminating the welding heads and transferring to the manufactured product. Due to this lubricant loss and subsequent gearbox failure, a refurbishment of the gearbox was required approximately every 3 months.

The cost of refurbishing each gearbox: 1 x HUB $400.00 2 x BRUSH GEAR SETS (SILVER COATED) £360.00 EACH 2 x 90mm BEARINGS $50.00 EACH Re-lubrication cost $27.00 APPROX The gearboxes are left & right handed when installed & dependent on the gearbox location removal & replacement could take anything from 1 to 3 hours at a cost of $75.00 per hour.

TOTAL $1397.00 (based on 2 hours to remove & replace a gearbox.)

TOTAL COST FOR ONE GEARBOX REFURBED 4 TIMES PER ANNUM $5588.00

THIS COST DOES NOT TAKE INTO ACCOUNT DOWNTIME AND TIME TAKEN TO REFURBISH THE GEARBOX.

The company has 3 welding lines each with 16 gearboxes operating on each, working 16 hours per day welding 2500 radiators each.

Total number of radiators welded each day is 7,500, Total 37,500 per 5 day week.


Our solution

Interflon Grease MP00 Interflon Grease LS1/2


Result

Since September 2010 the company has used Interflon products in a number of gearboxes on 1 of the 3 welding lines. In 13 months none of the gearboxes using Interflon products has been refurbished. The cost for one gearbox using Interflon products: Interflon Grease MP00 1.5ltr $47.25 (Gearbox) Interflon Grease LS1/2 200ml $7.46 (Bearings) Interflon Grease LS1/2 Simalube 4 (Based on being set for 12 months) $119.80

Cost to administer Interflon products re-install gearbox 2 hours (Approx) $75.00 Per Hour. 2 hours Total $150.00 Total Cost $324.51

These customers already saved between 7 and 11%:

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