Frequent machine breakdowns may not be solely due to the machine itself.
Frequent shutdowns of factory machines, even after replacing critical parts, may not be solely due to the machines themselves. The "quality of compressed air" is another cause that should not be overlooked.
In this case study, a factory experienced recurring mechanical failures during production, leading to discontinuous production, increased maintenance workload, and higher production costs.
Problems encountered on-site
The factory experienced frequent machine shutdowns and various abnormalities, such as:
- Temporary machine stops during production
- Unusual noises
- Vibrations
- Internal parts seizing
- Spindle problems, even after recent replacement
Even after replacing the spindle unit, the machine continued to shut down repeatedly, necessitating further investigation into the cause.
Cause found: Contaminants in compressed air
Upon checking the compressed air quality with a Particle Counter, it was found that the compressed air system contained a large number of contaminants, such as water from the air system, oil mist, dust, debris, and various small particles.
For machinery using high-speed spindles, compressed air plays a crucial role in delivering lubricating oil to the bearings within the spindle.
If the compressed air used contains contaminants, the lubrication system may not function efficiently, and this can be one of the reasons for machine damage or shutdowns.
Solution: Install a 3-in-1 Multi Dry Filter
To solve this problem, a 3-in-1 Multi Dry Filter was installed to improve the quality of compressed air before it entered the machinery.
The 3-in-1 Multi Dry Filter is a compressed air filter that helps reduce contaminants in the air system, such as water, oil mist, dust, and small particles, leading to cleaner compressed air.
This product is suitable for factories that want to reduce frequent machine breakdowns, minimize production line shutdowns, and ensure stable machine operation.
Filter selection should be based on actual on-site conditions.
The compressed air system environment varies from factory to factory, and different types of machinery require different air qualities.
Therefore, filter selection should consider actual on-site conditions, the type of machinery, the problems encountered, and the air quality required by the machinery to ensure the most suitable model for the application.
Results after installation
After installing the 3-in-1 Multi Dry Filter, it was found that contaminants in the compressed air, ranging from 0.3 microns and larger, were reduced to zero.
Previously, machine breakdowns occurred approximately every 3 months. After improving the compressed air quality, no machine shutdowns due to the same cause were observed for a period of 1 year.
This result allowed the machines to operate more stably, reduced the risk of production line shutdowns, lessened the maintenance workload, and ensured continuous production.
Why is compressed air quality important for machinery?
Compressed air is not only an energy source in factories but also relates to lubrication systems, control systems, and the internal operation of machine parts.
If compressed air contains water, oil, or dust contaminants, it can lead to faster wear and tear of internal parts, causing frequent machine breakdowns or unexpected production shutdowns.
Installing appropriate compressed air filters, such as the 3-in-1 Multi Dry Filter, is therefore one way to prevent frequent machine breakdowns and extend the lifespan of equipment in the production system.
What type of factory is the 3-in-1 Multi Dry Filter suitable for?
The 3-in-1 Multi Dry Filter is suitable for factories experiencing these problems:
- Frequent machine shutdowns during production
- Frequent breakdowns of CNC machines or other machinery
- Spindle problems, even after recent parts replacement
- Compressed air systems with water, oil, or dust contamination
- Desire to reduce recurring maintenance issues
- Need to increase production line stability
- Desire to improve compressed air quality before it enters the machinery
Summary
This case study demonstrates that the quality of compressed air directly affects the stability of factory machinery. If compressed air contains water, oil mist, dust, or other contaminants, it can cause recurring machine problems and production shutdowns.
Installing a 3-in-1 Multi Dry Filter is therefore one approach to prevent machine breakdowns, reduce production line shutdowns, and enable the production system to operate more continuously.
If your factory is experiencing frequent machine breakdowns, machine stops during production, or you suspect that the compressed air system may have contaminants, checking the compressed air quality and choosing the appropriate filter may help reduce problems and enhance the stability of your production process.
Read more about the product at: https://thai.fakiki.com/pages/3-in-1-multi-dry-filter
Reference: https://www.maedauni.co.jp/casestudy/p388/
