VALUE ANALYSIS / VALUE ENGINEERING

FORGING CASE STUDY

A forging & machining company forges expensive crankshafts, machines them using conventional neat oils and cleans them with alkaline aqueous cleaners before heat treating them. Disharmony due to large carryover of the neat oil, poor demulsification properties of the cleaner and high salt residues, the crankshaft surface carries over residues which cause soot and surface defects after the heat treatment. Rejection levels 4000 ppm sent for rework or scrapping. Harmony usage of HAKUFORM 20-225 HSG RR Neat oil firstly ensures low carryover, the HAKUPUR 700 (low salt) cleaner does demulsifies the removed neat oil in the sump and ensures no carryover of either the used neat oil nor salts. No surface anomalies seen after heat treatment. Rejection Levels ZERO ppm.

Out of 70+ R&D Scientists in Kluthe Lab, 29 focus on advancing HAKUPUR Cleaners.

BEFORE

  • Neat Oil carryover
  • Poor cleaning/residues
  • Surface defects

AFTER

  • Neat Oil carryover reduced
  • Efficient Demulsification/superb cleaning
  • Zero ppm rejections

CKD CASE STUDY

An Automotive OEM exports CKD sheet metal panels to their sister company in South America, uses a rust preventive cum stamping oil in the press shop places the panels in steel racks applies VCI Film over the panels ships them overseas in sea containers. Disharmony due to conflicting chemistries of the stamping cum RP oil and the VCI Film, the OEM is facing consistent corrosion problems resulting in rework and scrapping at the destination plant. Losses due to urgent airfreight of materials, scrapping and rework. Harmony usage of NOX-RUST R-823 as a stamping cum RP oil ensures high rust protection in extremely humid and condensing climates. Application of DAUBERT VCI Premium Metal Guard Film reduces moisture ingresses due to its multi-layered technology and low MVTR properties, provides excellent protection in compatibility with the NOX RUST used. No significant rust issues since implantation since early 2007.

BEFORE

  • Conflicting chemistries
  • Rusting
  • Rework and Scrapping

AFTER

  • Harmonised chemistries
  • Protection during shipping
  • No Rust

CASTINGS CASE STUDY

A exhaust fold manufacturer, machines their casting using conventional water soluble cutting oil cleans the rings in an ultrasonic cleaner using neutral aqueous cleaner applies rust preventive oil through a dip process.

Disharmony due to presence of chlorides in the water used in the water soluble coolant and the resultant carryover of chlorides in the cleaner bath and along with the part even after RPO application. Flash rust seen within 2 days in June to August 2010 prior to shipping the parts to nearby automotive OEM. Loss due to rejection in a month: INR 2.8 Million.

Harmony usage of HAKUFORM 70-84 Water soluble firstly ensures low carryover of chlorides, HAKUPUR 445 (low salt with chlorides complexing agents) Cleaner ensures no chloride is carried with the part Application of NOX RUST 307 (low aromatics & sulphur free) dewaters the part well and applies a thin RP film. No significant rust issues seen since August 2010.

BEFORE

  • Conflicting chemistries
  • Rusting
  • Rework and Scrapping

AFTER

  • Harmonised chemistries
  • Protection during shipping
  • No Rust