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Case Studies

Leading Indian Auto Part Manufacturer Reduces Cost per Unit by 16% with TRIM^® OM 222

Accurate Product Corporation has emerged as the leading manufacturer in India for components ranging from grease fittings and cups and relief valves to air breathers and precision turned parts, among other critical automotive parts.

Their products are available in over 72 countries, serving almost every major original equipment manufacturer (OEM) for automotive producers in India, in addition to others worldwide.

THE CHALLENGE

Accurate conducts various drilling, thread forming, and grooving operations on multi-spindle automatic machines and other equipment to create high-quality automotive components. As the company grows, management remains diligent about improving productivity without sacrificing part quality.

To fight rising operating costs, Accurate used the same economically priced neat oil for 40 years. However, after reaching the limit of the fluid’s capabilities, the only option remaining for the company was to explore an oil upgrade.

THE SOLUTION

Accurate switched to TRIM^® OM 222, a high-performance straight cutting oil specifically designed for hard-to-machine materials. With superior lubricity, OM 222 excels at preventing the formation of built-up edge that’s common with tough ferrous metals and stainless steel alloys. The versatile product is also compatible with nonferrous metals.

This fluid is ideally suited for Accurate’s manufacturing operation, which includes the use of a wide array of materials on a daily basis. Because OM 222 is low odor and light in color, it offers better operator acceptance than similar fluids.

THE RESULTS

With shop layout, ergonomics, and workflow already optimized, the only way to improve productivity was to transition to a higher performance cutting fluid. OM 222’s enhanced lubricity and cooling ability allowed Accurate machine operators to significantly speed up production without reducing part quality.

In the first phase of testing OM 222’s capabilities, operators reduced cycle time from 8 seconds down to 7.5 seconds per part. After proving machines could consistently produce high-quality results, operators shaved even more from cycle times. In the second phase of trials, operators reduced time per unit to 7 seconds, and finally to 6.8 seconds in phase three.

By cutting 1.2 seconds from cycle time, Accurate increased daily output by 1,500 components. Even though OM 222 costs three times more than their previous cutting fluid, the drastic increase in productivity lowered the cost per unit by 16 percent, paving the way for significant growth in revenue.

THE NUMBERS

Increased output by 1,500 components per day
Reduced cycle time from 8 to 6.8 seconds per component
Lowered cost per unit by 16%