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Profit Finders Case Studies


 Greenhouse Gas Reduction

Situation:

This Fortune 500 client was receiving monthly natural gas and electricity bills but had no data to determine with accuracy how their energy monies were spent. The company has a major commitment to sustainability and GHG (greenhouse gas) reduction. Without hard data it was not possible to implement GHG Reduction Programs and measure ROI.

Process Improvements:

Profit Finders technology including natural gas / electricity metering was implemented to capture baseline data on key processes that consume energy. Detailed energy consumption data was captured, archived and analyzed along with important production process parameters. Reports and dashboards were developed to document energy cost reductions related to various operational changes.

Benefits Delivered:

A significant reduction in annual energy consumption with no adverse impact on product quality.

  •  30% reduction in natural gas consumption


 Increased Labor Productivity

Situation:

This client manufactures welded metal tubes. Their coolant reservoir was manually controlled. As a result operators were spending too much time with coolant issues and mill efficiencies suffered.

Process Improvements:

Profit Finders technology was implemented to monitor and control the coolant reservoir 24/7. This allowed the factory to move towards a steady state level of coolant concentration, pH and temperature that is ideal for production efficiencies.

Benefits Delivered:

The Profit Finders system watches over the coolant chemistry so mill operators don’t have to worry about it – they can focus on running the mills. Benefits include lower operating costs, improved efficiencies, and the ability to implement a professional continuous improvement program. Labor time to maintain coolant sumps was reduced by 90% and coolant consumption per ton was reduced by 27%.



 Reduced Water Cost

Situation:

This client has several large parts washers located within their facility and all use multiple steam plates for heating. On occasion one of the steam plates will start to leak and contaminate their condensate return lines back to the facility boilers. This causes several costly issues including:

  •  Dumping large quantities of water that is above their
    discharge limit
  •  Poor cleaning of parts as saturated steam now dilutes the chemical bath
  •  Lost production as it takes significant time to locate the washer which is having the steam plate leak so corrective action can be taken.

Process Improvements:

Special high temperature conductivity sensors were installed to continuously monitor the condensate return from each washer.

Benefits Delivered:

Now when a steam plate begins to leak, Profit Finders’ system immediately detects the increase in condensate return conductivity and automatically alarms the customer as to which washer has the steam leak. This saves on lost production time and manpower to locate the bad steam plate. It saves water. It also reduces energy costs from not having to heat up as much make up water.



 Reduced Chemical Cost

Situation:

This client uses large quantities of an alkaline cleaner to clean locomotives before painting. They were using manual control methods to add the cleaner to their washer.

Process Improvements:

Profit Finders technology was implemented to monitor and control the cleaner concentration automatically to improve quality and reduce costs.

Benefits Delivered:

Improved cleaning performance and virtually eliminated quality defects. Realized a 34% reduction in chemical use per unit of production.



 Increased Market Share

Situation:

This client has a parts washer used in the powder coating of parts designed for automotive manufacturers. They were bidding on contracts to gain new business in the very competitive & quality conscious automotive industry.

Process Improvements:

Profit Finders technology was implemented to monitor and control key process parameters in their coating process. The Profit Finders process monitoring & control equipment allowed our client to effectively differentiate themselves from the competition and win a major contract from the most quality conscious automobile manufacturer in the world.

Benefits Delivered:

Increased market share, sales and profits. Our client landed a prestigious & significant new customer and the contract has been renewed for subsequent model years. They are also expanding their business into different industries by once again using their process control & continuous improvement systems as a strategic advantage versus their competitors.


 Improved Product Quality / Reduce Scrap & Rework

Situation:

This company was having challenging product quality problems in their Finishing Department. They made the decision to upgrade their operations and incorporate Profit Finders technology.

Process Improvements:

The Profit Finders system installed monitors, controls, and alarms the temperature, conductivity, and pH of the chemical baths in their pretreatment washer. Now that the tunnel washer process is on a continuous improvement cycle, important coating line parameters are being tied into the system so similar improvements will be enjoyed.

Benefits Delivered:

Improved product quality, lower rejects/rework/scrap, and lower chemical consumption. Also, continuous improvement projects are being implemented to reduce energy consumption.


 Reduced Wastewater Cost

Situation:

This client in their continuous improvement planning process identified water conservation as a top priority.

Process Improvements:

Profit Finders technology was implemented to monitor, gather data, and alarm an automated high volume immersion phosphate line that is run 24/7. Baseline data was gathered for a period of time before changes were made. The baseline data allowed us to work with our client to make informed decisions on the ideal settings for city water input, tank counter flows, and drain to sewer flow rates.

Benefits Delivered:

Cost reductions related to both water and sewer costs with improved product quality


 Brought First Shift Management to Second/Third Shift Through Technology

Situation:

This client was having poor line efficiencies and product quality in second shift compared to first shift.

Process Improvements:

Profit Finders technology was used to monitor and alarm key process parameters and make automatic adjustments. Sensors were programmed to take readings every 10 minutes and all critical data was made available for viewing from any PC connected to the Internet. Managers at home can view evening operations via Internet. Second shift supervisors and operators have detailed reports and real-time data to compare their performance to first shift.

Benefits Delivered:

A dramatic reduction in the gap between first shift versus second shift performance. The result was increased production, lower unit costs, and increased profits.


 Increased Process Engineering Productivity & Continuous Improvement Results

Situation:

This client had a number of probes and sensors in place in their cleaning / paint pretreatment line, but was struggling to convert data into information to drive continuous improvements in the department. They had downsized their process engineering team and were suffering from data overload – they had no time to convert data into actionable information.

Process Improvements:

Profit Finders installed a controller and made connections with existing probes and sensors. All data was archived and imported into a web-based customer portal.

Benefits Delivered:

Management reports are automatically generated by the Profit Finders technology. Costs per hour of operation are calculated and compared to baseline data to document savings. With no addition to the process engineering team, additional lean manufacturing / continuous improvement projects were completed to drive out waste and increase the bottom line.



 Low Hanging Fruit - Energy Cost Reduction

Situation:

This client was firing up gas burners to bring chemical baths up to temperature without any monitoring. When operators arrived in the morning they immediately fired up burners. Burners were not turned off until the very end of the workday. Often bath temperatures were higher than required.

Process Improvements:

Profit Finders technology was implemented to capture baseline data on several chemical bath variables including temperature. Analysis of the temperature data indicated that tank burners were being fired up over 60 minutes sooner than required and being shut down over 30 minutes later than possible. As a result policies for start up and shut down were set saving over 1 hour per day of run time per burner. Also, an automatic alarming system was implemented to address bath temperature excesses.

Benefits Delivered:

A six-figure reduction in annual energy consumption with no adverse impact on product quality.


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