Challenge:

Flexxaire needed consistent coolant levels to maintain part quality, especially for unattended overnight runs. Without reliable coolant monitoring, machines would often run out mid-shift, leading to stops, scrap parts, and fluctuating sizing and surface finishes. With machinists juggling multiple machines and an unstaffed night shift, this challenge was magnified.

Solution:

The FlexxCool system allowed Flexxaire to keep coolant levels consistent and concentration stable, eliminating the need for manual monitoring and adjusting. This system now ensures uninterrupted runs, automatically replenishing coolant and maintaining the correct concentration, even on long 30-hour runs overnight and into the weekend.

Value:

With FlexxCool in place, Flexxaire achieves longer, high-quality production runs, saving time and reducing scrap. While FlexxCool handles coolant management, skilled machinists can now focus on optimizing setups and improving machine efficiency, resulting in longer unattended runs. This implementation has led to better-quality parts, a safer machine shop, and increased productivity by repurposing manpower to more critical tasks.

“We used to come back to stopped machines and scrap parts; now we have 30-hour runs with zero operator intervention, and that’s a game-changer.” Frank Rodrigues, Director of Operations