Alternative Solvent Based Ultrasonic Parts Washer
Initiative to Reduce Labour Costs, Increase Productivity and Minimise Effects on the Environment by the Implementation of an Alternative Solvent Based Ultrasonic Parts Washer.
The installation of new equipment for the cleaning of automatic transmissions, valve bodies and other ancillary motor parts at Rowell and Searle in Adelaide, South Australia has resulted in a significant 40 percent reduction in cleaning solvent used, and an annual saving of approximately $4,800.
Labour cost savings in the vicinity of 20-30 man hours per week resulted in an annual saving of $29120-$38480 based on a tradespersons hourly rate of $28 per hour (including on costs, superannuation, WorkCover etc.)
The initial investment cost of the machine was $22,000 and was easily recouped within the first.
Employee exposure to hazardous chemicals and solvents has been substantially reduced.
Background
Rowell and Searle is a South Australian company employing 16 staff at its premises in the Adelaide central business district. Since its establishment in 1945, the company has developed into a fully diversified automatic transmission and power steering workshop employing modern technology to assist in the previously mundane labour intensive tasks associated with this type of work.
The Process
The cleaning of automatic transmission housings and gearing was an extremely labour intensive task requiring approximately one to one and one half hours to clean manually using a brush and an oil based solvent (143 Petroleum Spirit). When left overnight this solvent evaporated leaving an oily/greasy residue, which was then tipped into a hot bath and then passed through the separator.
Staff involved in the manual cleaning process were exposed to the solvent fumes and to the chemicals used in the process. The use of solvent 143 posed some serious health problems to staff.
Cleaner Production Initiatives
The company’s decision to invest in the new ultrasonic technology has increased productivity, improved the work environment, greatly reduced the environmental impact and benefited the company financially.
Each tradesperson is required to wash their own parts in the ultrasonic parts washer in the one central area within the workshop.
The “Grease Monkey” ultrasonic parts washer uses a water-based cleaning powder. The unit has a thermostatically controlled heat cycle, which has a maximum operating temperature of 70 degrees Celsius.
Ultrasonic cavitation and implosion brought about by mechanically produced sound waves has the effect of speeding up dissolution and displacement of oil and grease contaminants.
Oil, grease and other contaminants float to the top of the bath where a unique skimming system removes the contaminants to the separator.
Filtration is a three-stage process, which prolongs the life of the cleaning solution.
Advantages of the Process
The process has considerably reduced the usage of solvent 143 by approximately 40 percent, saving $400 per month on this product alone. The powder used in the Ultrasonic parts washer is relatively inexpensive ($80 per twenty litre drum) and lasts approximately 6 months, ie. cost of $14 per month. The overall cost saving per month is roughly $386 or $4600 per annum.
The “Grease Monkey” system is far less hazardous and extremely user friendly due to the simplicity of the operation. In occupational health and safety terms, operators are less exposed to the fumes from solvent 143 and the danger of spillage. The system protects the user from solvent vapours and contact with chemicals.
The introduction of this system has resulted in increased productivity. The time saved by using the ultrasonic parts washer as opposed to manual cleaning of parts is approximately one to one and one half hours per transmission.
Based on the transmission rebuilds of twenty per week, there is a labour cost saving of 20-30 hours per week. Tradespersons labour costs including on-costs (superannuation, WorkCover etc.) amount to $28 per hour. This is a cost saving of $560-$740 per week, or $29120/$38480 per year.
The resultant increase in productivity is reflected in faster job delivery and client satisfaction.
| Total Outlay Including Annual Maintenance | $ 22,100 |
| Savings per Annum | $ |
| Savings in use of solvents | $4,600 |
| Labour Cost Savings | $38,480 |
| Total Savings | $43,080 |
| Payback Period | 6 Months |
Cleaner Production Incentive
The main motivators were the desire to increase productivity, minimise environmental and OH&S impacts.
Barriers
No barriers encountered.
Further Developments
The project is ongoing and is continuing to have an effect on the reduction of environmental impact by the lowering of waste generation brought about by lower solvent usage and a reduction in wastewater volume.
Contact:
Mr Peter Stewart
Rowell & Searle Auto Transmissions Pty Ltd
217 Pulteney Street
Adelaide SA 5000
Phone: 08 8223 1844
Fax: 08 8233 1370