Optimize performance of conveyor system.
CB began with an inspection and detailed audit of each conveyor system in the plant using proprietary software to calculate the belt tension requirements and conveyor capacities. Our analysis determined that 52% of the systems were “over-belted” – the belting installed was bigger, thicker and heavier than was required to maximize system performance.
With a full understanding of the system performance and capabilities, CB’s technician was able to recommend the right Value Fit belt solution to ensure the system was working at peak efficiency while delivering more than $95,000 in immediate cost savings and a lower overall projected operating cost year-after-year.
A 10-week delivery time for a critical motor part would significantly impact production capacity and costs. Clearly an alternative solution was needed – and needed fast.
A CB technical service representative quickly went onsite to evaluate the application and take load and physical size ratings. His analysis identified an alternative motor and gearbox solution that could be installed in a matter of days – as opposed to 10 weeks. The CB solution not only had the manufacturer up and running again in a week, but also resulted in a 50% cost savings compared to using the part that was originally suggested.
Maintain quality and cost efficiency while achieving environmental responsibility objectives and ISO 1400 certification standards.
The client challenged us to recommend alternative lubricant products that would be more environmentally friendly without compromising equipment efficiency or increasing costs. CB’s technical assessment also revealed that their current hydraulic fluid was gumming valves and leaving sludge build-up in the reservoir tank. Leveraging exclusive partnerships with global lubricant manufacturers, CB sourced the right product solution that not only met the environmental demands but also improved performance and extended product life from 3,000 to 8,000 hours avoiding potential downtime costs in the range of $100 – $120 per minute.
Reduce energy costs while minimizing investment in retrofits.
The client came to CB for a solution that would deliver a significant reduction in operational energy costs without spending to upgrade existing rotating equipment. After a thorough on-site evaluation of the plant operations, the local CB representative recommended utilizing an energy-efficient family of deep groove ball bearings with the existing rotating equipment to reduce energy costs and improve equipment reliability. The CB solution has not only delivered up to 30% energy reduction in rotating equipment, but also improved bearing reliability and reduced downtime.
Reduce total operating costs and improve efficiency of motors.
CB’s technicians first measured the loads and analyzed nameplate data of all in-service motors. Then, using proprietary software, we compiled a complete motor inventory along with a comprehensive recommendation identifying inefficient motors, as well as specific upgrade and repair opportunities. From there, we calculated the total costs savings achievable with ROI and customer payback forecasts.
By implementing the CB plan, which included replacement of inefficient motors with NEMA premium efficiency motors, the client achieved first year cost savings of approximately $40,000. That figure is projected to grow to nearly $500,000 in total cost savings over the next 15 years.
Improve safety item inventory management to reduce costs.
After conducting an audit of the client’s safety item procurement and inventory management processes, CB identified three key issues: Purchasing used multiple distributors to source items resulting in higher than necessary inventory levels. There were no access controls on safety item stores, and stock keeping procedures were manual and sometimes inaccurate. To achieve the client’s objectives we recommended installing product vending machines at various locations in the plant to dispense the most-used safety items.
This innovative solution enabled effective inventory tracking and usage monitoring without compromising employee access to items required to perform their jobs safely. In the first month, inventory-monitoring costs dropped by more than 30% and the machines paid for themselves within nine months.
The client needed onsite MRO sourcing resources to support operations and ensure better technical support for their maintenance team.
The client came to CB with a need to better manage its MRO procurement and transactions. After a comprehensive review of their operations, CB provided two on-site resources focused on the areas of parts sourcing, inventory management, and cost reduction projects. CB also implemented a reliable dispensing solution to manage critical safety items required 24/7. The results have been dramatic and immediate with an average savings of 17% realized on their annual purchases – all documented and signed off by the client.
With 240 MRO-related suppliers, there was a real need to streamline the supply channel and provide sourcing support to the client’s entire operations team.
The client’s goal was to reduce or eliminate non value-added procurement practices and processes to reduce costs. After a thorough audit CB was able to define and implement solutions that improved the procurement process, management of consumables, and organization of storerooms. CB also invested in resources to build a complete MRO parts database; including critical items that could interface with both the customer’s enterprise system and CB’s order application system. Implementation of these solutions was a prerequisite to optimizing inventory levels, faster re-ordering, and reduced downtime. CB’s client realized an average of 25% of their annual purchases in savings over a two year period by: