At a recent compressed air audit at plastic molding plant we found that bad design of compressed air system caused a 500t molding machine to produce scrap, unpredictably, from time to time.
Client has just acquired this machine for $1.2mln to meet high throughput demand of their automotive client. With this scrap level they were at risk of missing delivery schedule, which would automatically kill this contract and disqualify them from any further serious work in the industry.
Fixing the fault helped our client meet tough production schedule. Change also allowed reducing pressure and cutting energy cost, so incentives were applied.