In this example case study, we use data from a customer that manufactures a large volume of automotive parts. The customer produces and inspects steering racks that are about 20 inches long and each one needs to be inspected in both directions.
Their parameters would be like other manufacturers producing automotive parts such as engine locks, cylinder heads, crankshafts, camshafts and steering racks.
The customer in this case study was facing the following challenges:
- A need for a consistent and reliable process to ensuring that each part is thoroughly inspected.
- A reduction in processing time without a reduction in the quality of the non-destructive test.
In most non-destructive testing processes only one of these needs can be satisfied at a time. Until now, adding more machines, adding shifts or adding operators would not overcome both challenges.
Magnaflux is focused on solving customer pain points and improving the NDT processes. Multi-directional magnetic particle technology has expanded the capabilities of high speed inspection and the new Universal WE Multi-Directional AC Magnetic Wet Bench is designed for high speed, 100% inspection targeting surface defects.
- The Universal WE can double inspection speed by magnetizing parts in multi-directions in a single shot
- Allows full inspection of longer parts, up to 35.4 in (90 cm), without requiring an auxiliary coil
- Speeds up part processing with a large automated surface shower
Based on testing and real-world expertise, the following example case study was put together to demonstrate the savings potential of the Universal WE Multi-Directional AC Magnetic Wet Bench compared to standard uni-directional wet benches.
Baseline data from a standard uni-directional magnetic particle equipment inspection process:
7,000 parts/week x 1 minute/part x 1 hour/60 minutes x 52 weeks/year x $25/hour = $151,666/year estimated operating costs
The extended multi-directional shot on the Universal WE can cut inspection time in half:
151,666/year x 50% time saving = $75,833 savings
How was this calculated?
7000 parts/week x 1minute/part = 7000 minutes/week = 116.7 hours/week inspecting
The time saving adjustment for part length is:
Based on our data, the average processing time difference between multi-directional and uni-directional is 47%. Time savings are gained from inspecting a part once in both directions at the same time vs inspecting the part twice, in one direction and then the other. In our calculations we estimate the time savings as follows:
- 0-6 inches = 30%
- 6-12 inches = 40%
- 12-24 inches = 50%
- 24-36 inches = 60%
By combining your total part inspection time with the time saving percentage, we calculate:
116.7 hours/week inspecting x 50% = 58.3 hours/week saved
58.3 hours/week x $25 per hour = $1,457.50 per week saved
$1,457.50 week x 52 weeks/year = total estimated annual savings of: $75,833
Complete the interactive ROI Calculator with your actual numbers to see what your savings potential could be.
Published September 18, 2018