Worksite Improvement Case Studies

The Pharmaceutical, Cosmetic and Chemical Workplace

Hoses with hard steel wire cost three times as much to dispose of

A plant was using spring hoses for shampoo and conditioner and the local government imposed a industrial waste tax. That tripled the disposal costs for the hoses they were using. They wanted to avoid having to sort out the hoses according to whether they contained hard steel because it increased their labor costs.

Tens of thousands of bolts become charged with static electricity, a hazard to the workerseven after being crushed.

At a chemical production plant, they were using suction hoses to transport wet powdered chemicals before they reached the drying oven. One day, they measured the static electricity and found a charge between 20 and 30 kilovolts, an extremely dangerous level for human workers.

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The Semiconductor and Precision Instrument Workplace

An abrasive compound clogging inside a hose stops the production line

At a plant that manufactures silicon wafers, PVC hoses were being used to feed silica grinding powder used in their wafer grinder. But the silica powder got clogged in the hose, causing the production line to stop. The workers would use a hammer on the hose to get it running again.

Hoses for discharging chemical waste degrade quickly, requiring frequent replacement.

At a factory producing printed boards, the effluent had to be brought to a certain pH level in the discharge process to prevent water pollution. Their process involved injecting sulfuric acid, hydrochloric acid and sodium hydroxide to adjust the pH level. This caused their PVC hoses to become brittle and otherwise degrade quickly. Because they needed the hoses to be flexible, they had to replace the hoses frequently.

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The Machinery Manufacturing Workplace

Stiff hoses have to be softened with hot water before use

At a plant where our customer produces precision machinery, they used spring hoses for product assembly and delivery. They fastened a clamp on the barb fitting nipple, but insertion was not easy when mounting the hose. They used hot water to soften it, but that increased time it took to complete the insertion, and they had no hot water when making delivery.

An over-tightened clamp cuts the hose, resulting in a water leak

A clamp had been over-tightened at a plant, cutting into the hose and causing a water leak. When they moved into a new plant, there was electrical wiring near the location of the leak, so they needed to rethink their entire hose piping configuration.

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The Plastic Molding Workplace

Raising the mold temperature causes liquid to leak onto the product, resulting in product defects.

To reduce the defect rate, a customer raised their die temperature from between 60 and 80℃ to between 80 and 95℃. This temperature increase however, caused the rubber hose circulating the hot water for regulating die temperature to become brittle sooner than expected. This resulted in cracks, and hot water leaking onto the product again, causing more product loss.

During a color pigment changeover, static electricity causes pellets to get stuck in the hose, causing products with different colors to get mixed together.

A plant producing curved mirrors uses PVC duct hoses to convey pellets. When they switched colors, pellets would get stuck inside the duct hose due to static electricity, and the customer needed to find a solution that would reduce the losses they were incurring.

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Factory Equipment Hose Examples

Water leaks from the hose and coupling are a concern after years of use

In a paint booth for plastic car bumpers, static electricity generated in the drying process would cause dust to stick to the bumper before the painting. To prevent this, they built a water tank to add moisture. The hoses used to circulate water for the tank were installed at two different levels of the tank. The company was concerned about leaks occurring at the clamp and nipple some years later as time passed.

When hoses are replaced, the clamps are completely rusted and do not move.

A customer fastened a spring hose with a barb fitting and clamp for their plant equipment. About every five years, they had to replace the hoses, at which point, they found the clamps to be completely rusted on. Additionally, the barb fitting did not go into the spring hose easily and would sometimes break in the process.

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The Food and Beverage Workplace

Machinery vibration causes sanitary beverage hoses to become displaced and make a lot of noise!

Sanitary beverage hoses were making a lot of noise due to machinery vibration and were becoming displaced. They tried inserting a hose at the connection point to absorb the vibration, but then they had problems with the heat and acetic acid used during cleaning, meaning that sanitation was also an issue.

Stainless steel pipes are difficult to lay out and the material inside is not visible.

Lacking a heat-resistant hose, a customer used a stainless steel pipe for a food equipment pump that provided a pressure feed and a vacuum. They came to us and asked if we had a heat-resistant flexible pump that would allow them to check the material inside, and we looked for a solution for them.

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