Client Overview

The project was executed for a high-precision manufacturing facility that produces critical fuel-injection components. The production line consisted of imported grinding machines used for ultra-accurate component finishing, where tight geometric tolerances and high surface finish quality were mandatory. The machines were relocated from a previous centralized coolant setup into an existing shop floor with limited space, creating the need for a compact, reliable coolant filtration and temperature management solution.

Challenges Faced

Ultra-High Accuracy Requirements
Grinding operations required roundness levels of approximately half a micron and concentricity of about one micron, demanding very fine coolant filtration to maintain process stability.

Severe Floor Space Constraints
The production line consisted of six grinding machines but there was no space to install individual filtration systems near each machine. A conventional setup would have consumed nearly 60 percent of the floor space per machine, making it impractical.

Need for Fine Filtration and Temperature Control
The process required ultra-fine coolant filtration along with coolant temperature management to ensure consistent accuracy and surface quality.

High Reliability Expectations
Given the critical nature of the application, the solution had to deliver stable long-term performance without causing machine stoppage.

Solution by Lex Technoaid

Lex Technoaid implemented a Centralized Coolant Filtration System designed specifically for the six critical grinding machines, overcoming both space and precision challenges.

1. Remote Centralized System Layout
   Due to limited space near the machines, the filtration system was installed away from the production line, with:

• One line carries the used coolant to the filtration
  
• One header line supplying clean coolant back to all six machines
  

2. Ultra-Fine Filtration for Grinding
   The system achieved a filtration level of approximately 3 microns, suitable for high-precision grinding applications.
3. Integrated Coolant Temperature Management
   The system included coolant temperature control, supporting stable machining conditions and consistent quality output.
4. Designed for Continuous Operation
   To prevent downtime, the system featured:

• Standby consumable filters enabling changeover without stopping machines
  
• Minimal stoppage only during compact band filter roll replacement, typically completed within a few minutes
  

5. Built for 24/7 Production
   The solution supported continuous 24/7, 365-day operations, aligned with the facility’s non-stop production mandate.

Outcome

• Met Required Process Capability Levels
  The system enabled the facility to achieve the required CPK and CMK levels, supporting statistical quality control and process validation.
• Proven Long-Term Reliability
  The system has been running successfully for approximately five years in a continuous production environment.
• Significant Cost Savings
  Compared to importing a similar system, the client avoided spending approximately 2.5 times more, while achieving comparable or better performance.
• Operational Confidence and Support Advantage
  The facility benefited from fast local service support, with response times of around six hours and ongoing assistance for operation and maintenance.
• Repeat Orders and Expanded Engagement
  Due to strong results, the customer placed repeat orders for similar needs and additional deep drilling applications on other critical machines.