Revolutionising Fluid Management With OEMETA

For many organisations, particularly larger enterprises, fluid management and maintaining optimal fluid performance whilst ensuring compliance and minimising costs has become a significant operational challenge. OEMETA, recognised for its advanced cutting fluids and oils, has developed a comprehensive fluid management service that positions the company as a leading provider of not just innovative cutting fluids, but also the complete management solution.

As OEMETA UK Managing Director, David Woodford explains: "If you're looking to implement fluid management on your shop floor, or if you’re not happy with your current provider and you're looking for an alternative, that's where OEMETA can fit in."

The Challenge for Modern Manufacturing
The challenge of managing cutting fluids is multifaceted, as David Woodford observes: "When you start to get to large, complex machines, bigger factories, supply chains, consignment stock and the subsequent waste disposal, you have to think seriously about who's going to be doing this. You can either train up your own people or bring somebody in who has all that experience and just do it from day one."

Many companies face a harsh reality. "Smaller companies can typically look after 10 or 20 machines themselves, but when you start to get to large, complex machines and larger businesses with more machine tools, those companies don't have the internal resource and expertise to run the products effectively," explains Woodford.

OEMETA's experience suggests significant market demand for either setting up onsite fluid management, or for businesses where this already exists, an alternative solution. "Our experience with certain companies is that they're not getting the most from their existing providers and they are unaware of any alternative providers or offerings," observes Woodford.
A Different Approach
Unlike traditional approaches that focus on supplying fluid in volume, OEMETA emphasises process optimisation. "What competitors are doing is going in with inexpensive products and selling them in volume," explains Woodford. "They're selling products cheaply, but their consumption is extremely high, so they're selling cheap, and selling lots of it. Our approach is to sell a better-performing product and sell a lot less of it."

This philosophy centres on continuous improvement. "Rather than just managing top-ups, our approach is about process optimisation, rather than just supplying and managing a product. We're putting in products that are unique on the market and some are new technologies. What we are trying to do is continuously improve our products, services, and the management solution for customers whereas competitors provide more of a monitoring rather than improving structure."

Louisa Johns from OEMETA emphasises the knowledge gap: "When we go to shop floors where they have a fluid management agreement in place, the support they get can be sub-standard. The internal staff don't have the knowledge and expertise that we bring. Every time we go somewhere where there is a competitor providing fluid management, there's barely any support. What we do is offer so much more."

Comprehensive Service Integration
OEMETA's service encompasses the complete fluid lifecycle. "We control the stock levels, bring the stock in, and manage distribution into machines and processes. We do all the testing and analytics, all the supporting data, all the health and safety documents," explains Woodford. "We work to improve the process, extend product life, and when the fluid is ready to be changed, we do all the machine cleaning, waste collection, and organise disposal."
One example is at a large engine manufacturing facility in the Midlands, OEMETA manages 42 machines that run 24/7 and require 12 different fluid types. “We have staff permanently located on-site on different shifts, and the scope extends beyond cutting fluids. We also manage their wash systems, chemical treatment plants, and do all the titration testing. The cost savings and efficiencies we deliver more than cover the cost of our staff on-site full-time," explains Woodford.

Louisa Johns highlights the bespoke nature: "The requirements and the subsequent solution is bespoke to each shop floor. One company might want to reduce misting, one might want to look at material staining issues or corrosion. The knowledge and expertise we bring compared to competitors is a whole new level."

Central to OEMETA's offering is its cloud-based software system. "Customers can look at fluid consumption of machines, operating parameters, and the tasks being carried out by the fluid management team. They can sit from anywhere in the world and see whether tasks are being done," explains Woodford.

Proven Results
OEMETA's approach delivers measurable results. At one industry-leading aerospace customer: "We did a process improvement on their neat oil machining, and improved tool life by 30%. They also reduced fluid consumption and the associated costs of fluid and disposal by more than a third. This more than covers the cost of our engineer on site," reports Woodford.

"Their process stability and customer auditability have also been significantly enhanced because we are controlling the process. When they are audited by customers in the highly regulated aerospace industry, everything is in place, and they no longer face fluid-related audit issues anymore," explains Woodford.

For the engine manufacturing customer: "By identifying hydraulic oil leaks from machine tools into our fluid, we will reduce fluid consumption by 20%. We are also highlighting machine tool patterns of maintenance concern to the customer, which feeds into their preventative maintenance programme. We are not only assisting in extending machine uptime and maintenance cycles, but we are also delivering savings that will pay for our on-site technician. The cost savings will pay for our engineers within the first 12 months," calculates Woodford.

Johns emphasizes the value: "It actually pays for itself and takes the headache away from the customer. The full management and traceability, extended machine uptime and enhanced performance and component quality are all benefits stacked on top of the significant cost savings and reduced environmental impact."

Embedded Expertise and Innovation
OEMETA places qualified technicians permanently on site. "It's permanent. Our engineers are embedded into the company when a business agrees to a fluid management service. This enables predictive maintenance where we can set lower and upper limits for hydraulic oil contamination. If we're topping up beyond a certain point, that flags to maintenance that there's obviously a leak. We're almost an early warning system. We see all those issues developing. We do all the on-site bacteria monitoring, so from a health and safety point of view, the documentation is all covered," explains Woodford.
Innovation is central to the offering. "We're working with an aerospace customer where they have a requirement to reduce misting. Our R&D department is working on reducing that misting characteristic. We bring the latest technology to the customer because we understand their processes. There was a new technology that recently became available. We knew their process and forecast a 30% improvement to fluid and tool life – we're actually going to get more. Most companies find a supplier and ‘just go with them’ because it works to a small degree. What we're offering is something more proactive with more impactful results," says Woodford.

Managing Complexity and Sustainability
Modern manufacturing requires specialised expertise. "The material mix on the shop floor now means that our products have to be specialised. The ‘fire and forget’ products from 20 years ago are no longer there. Products are more sensitive and require the corresponding management," observes Woodford.

"We're always aware of legislation long before customers are, so we can position the customer to meet any pending legislation way in advance, rather than having surprise product changes," explains Woodford.

Environmental considerations are also integral. “Reducing consumption by 30% is a quick sustainability win. We also offer non-fossil fuel alternatives. Our products last forever if you don't contaminate them. We help reduce contamination, which extends life dramatically," notes Woodford.

Cost-Effectiveness and Market Position
Johns reinforces the market education need: "The cost-saving potential around fluids is huge. We quite often ask what customers are paying for competitor products. Yes, the price looks attractive to buyers, but they don't realise they will be using twice as much fluid. We approach customers with a better-performing product. The cost savings come from process improvements, extending tool life, improved surface finishes and less scrappage."

"Although people know about fluid management, it's opening their eyes to what our fluid management can deliver. Alternative suppliers won't provide the level of service that OEMETA supports manufacturers with. There used to be alternatives between different providers, and companies would alternate if they weren't happy with one. However, the failings of some fluid companies to support manufacturers mean that OEMETA is the one true alternative for success," concludes Woodford.