TMD Communicates Clean Message With acs
Witnessing exponential growth as a world leading manufacturer of transmitters and specialised communication devices, TMD Technologies Ltd invested in Haas machine tools to support its growth. With the arrival of three machining centres that had to be continually cleaned in a sensitive area with specialist testing equipment, a ph-Cleantec 1000SRK universal low pressure cleaning system from Air Cleaning Systems (acs) soon followed the machine tool investment.
In September 2010, the Hayes based company purchased two Haas VF2’s and a VF4 machining centre to increase productivity and R&D work in the machine shop whist reducing subcontracting costs by over £100,000 a year.
However, with sensitive testing rigs and regular customer visits that include VIPs and dignitaries from the world’s armed forces, TMD has to maintain an impeccable image for its visitors. To ensure its new machine tools remain oil free and in as-new condition, the ph-Cleantec 1000SRK was the ideal choice. As Production Machine Shop Manager, Mr Dave Casey comments: “It took a number of years to approve the investment in machine tools, but the issue of potential oil, waste and residue affecting our testing departments as a consequence of the machine tools was a matter of urgency. As soon as we found a suitable solution, we purchased the ph-Cleantec unit from acs in March 2011.”
The manufacturer of microwave tubes, high voltage power supplies and transmitters for Radar, EW, Communications and other laboratory applications operates highly sensitive equipment, so cleanliness is a pre-requisite. As a company that has won two Queens Awards, one for Innovation and another for International Trade, TMD supplies customers such as Alcatel, BAE Systems, NEC, Northrop Grumman, Raytheon, Samsung, Thales, Toshiba and the world’s military forces. As Mr Casey continues: “Not only do we have very sensitive equipment in close proximity, but we have some extremely important decision makers regularly visiting our facility. We have just won a major military contract and business concerning highly sensitive and secretive equipment isn’t made without top level decision makers visiting us.”
Despite the main reasons for the ph-Cleantec unit being apparent, the additional benefits have been numerous for TMD. As Mr Casey says: “The first benefit we noted with the Cleantec unit was how easily it thoroughly cleaned our machine tools. We used to have a clean down each week. Where we used to use oily rags to clean, we now use the aqueous cleaning system and it saves us over 5 hours of cleaning time each week for each of the 5 staff in the machine shop. A machining centre can be thoroughly cleaned in 30 minutes and it used to take most of the day. We just wheel the mobile unit to each machine and plug it in. This ease of use and the time reduction actually gives our staff an incentive to clean.”
The ease of use is highlighted by the ability of the Cleantec to use coolant from the machine tool, eliminating the need for a bulky sump unit. The 1000SRK has a hose that can be put into the machine sump, so machine coolant can be heated and used as the cleaning fluid. In the case of TMD, the company uses a small barrel of coolant for the cleaning. This serves the purpose of topping up the coolant supply whilst cleaning.
However, the benefits are more far reaching for the TMD machine shop. As a department that mostly machines aluminium casings and copper components for the company’s core products, the processed swarf is of considerable value. Prior to the introduction of the low pressure cleaning unit that operates at 3 to 7.5bar with water or machine coolant heated to 95 degrees C, swarf would be blown from the work envelope into the swarf conveyor which would then transfer the swarf to a bin outside the machine. As with most machine shops, the swarf would be contaminated by the material from a previous job, reducing the value of the waste material. Now, the company can rapidly clean the machine after each job. This completely separates the swarf and increases the value of the waste. As Mr Casey comments: “TMD is in the process of selecting a new contractor for waste materials, as we have no doubt that we have considerably improved the quality of our waste materials. This will give us a better price for our waste. Additionally, the swarf is 100% clean and isn’t covered in oil.”
By washing the oily residue from the swarf and keeping the machining centres clean, the ph-Cleantec unit restricts bacteria levels in the coolant and improves sump life. Mr Casey believes: “By removing coolant from our waste swarf and keeping the machine tool clean we are saving at least 20% on coolant costs per machine. Over a 12 month period this will amount to over £2,000 per machine. With only three CNC’s, we will save over £6,000 each year. So, the ph-Cleantec unit will pay for itself in 12 months.”
In addition, Mr Casey also believes the ph-Cleantec system will improve the service life of the machine tool, which will also bring additional cost benefits. In conclusion Mr Casey says: “Initially the Cleantec machine was purchased to maintain the company’s impeccable image and improve the service life of the machine tools and the surrounding equipment. However, in a very short time since acquiring the unit we have seen a multitude of benefits, which we are still trying to quantify. We have only measured the coolant savings so far and this alone will pay for the Cleantec machine. When we quantify the savings from waste materials and machine servicing and reduced downtime, I expect the savings to be substantially more. We are delighted we bought the Cleantec unit from acs. In a very short space of time it has highlighted some major benefits and savings for our business.”
