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How Compressed Air Inefficiencies Hurt Manufacturing Plants

A productive and efficient company is a fierce competitor…

Compressed air management system

Competition is healthy; it brings out some of the best qualities in products and people.  Competition drives innovation, personal growth, quality and naturally weeds out the inferior.  However, while it can highlight a company’s strengths it can also reveal its weaknesses.  To remain on top, it is vital to always be on the lookout for advantages, ways to get ahead, cut costs, and increase profit.  In fact, there are career professionals hired and devoted to doing just that. Continuous Improvement Specialists, Sustainability Experts, Energy Auditors, Maintenance & Reliability Professionals, etc.  Many companies further employ practices and methodologies aligned towards remaining a strong competitor.  Lean Manufacturing (Six Sigma), Kaizen, Perpetual Beta, Fail Forward are just some of these initiatives many top competitors employ.

Manufacturing Plants Must Strive to Avoid Downtime

Most, if not all companies have infrastructures essential to their operation. Power, water, HVAC, steam, and compressed air are the essential utilities for manufacturing – most plants can’t run without them, at least not effectively.  To a plant, production is always KING, maybe only second to safety, but that’s a whole different category.  Meeting consumer demand with consistent quality is where most, if not all of managements eyes are set upon.  So, running the risk of downtime is simply not an option, especially if your job is on the line along with the company’s reputation.  A top competitor doesn’t stumble and fall and remain a top competitor. You might stumble, but falling is a quick way to the back of the pack.

Inefficient Compressed Air Systems Are Costly and Can Cause Shutdowns

Unfortunately, these essential systems aren’t without their flaws and drawbacks.  A compressed air system has several sources of inefficiency that can be costly if not addressed.  Waste and inefficiency aren’t the only parasitic costs either.  Downtime due to unexpected shutdowns can deliver a crippling blow at the wrong time.  You can imagine how bad the impact would be for a toy maker to lose production around Christmas time!  Where most of the common pitfalls lie are at the level of system transparency stemming from antiquated components or lack of a proper platform to host and represent data.  Poor transparency or visibility of a system poses an even greater risk and overall, these factors increase the probability of a shutdown.  It goes right to the heart of the aspects which threaten reliability by reducing the capability of the managers to be proactive.  Imagine if your car dashboard only displayed the traveling speed.  It wouldn’t be very helpful for determining how far you can go or, if the engine is running hot.

How Case Controls Can Help

With decades of experience, Case Controls have been addressing and solving these very issues.  We work to identify opportunities that increase efficiency, reliability, and plan for the road ahead.

  Moreover, we understand that no two plants are the same and to be effective we must account for the nuances of the plant operation.  Our focus is on transforming the compressed air system infrastructure into trusted and reliable asset with the goal in mind to help relieve a company of the anchor around their neck or the ticking time-bomb in the back room everyone regretfully tries to ignore.  By tailoring these solutions to meet the specific needs of the plant we are able to capture every advantage available and ultimately provide the peace of mind that allows attention and energy to be focused back on driving the company forward, maintaining a competitive edge and increasing the bottom line.

Compressed air is an essential utility, we know how valuable it is and understand the attention it deserves. For more information or to discuss your company’s specific needs, contact us today.