High-quality filtration is one of the most underestimated, yet critical elements of the automotive -manufacturing process. And Pall Corporation serves the market with sophisticated and durable filtration solutions that add value, enabling lean manufacturing by reducing waste, rework and providing asset protection.
The implementation of Pall filtration in two key automotive manufacturing facets—the vehicle assembly plant, and the engine assembly line—plays an essential role in maintaining overall operational efficiency. Often the domain of plant maintenance, the utilization of Pall products can be the undercard in plant quality control – but it’s the secret weapon for engineers who understand its importance.
Today’s automotive manufacturing process incorporates fluids in many processes—from paint to metalworking, on through to final testing, wherein transmission fluid is entrusted to fill and interact with the resource intensive transmission and powertrain at large.
In the metalworking process, honing and grinding serve to finish products. With so many working parts in automotive assembly, this is a critical function with no margin for error. Metalworking technicians are accustomed to flushing debris with recycled fluid, which also serves as a coolant in the process. But in the deburring and honing process, debris and even smaller particulate matter can critically damage otherwise good work.
As parts are finished, unseen fluid contamination can tarnish and damage surfaces leading to costly rework or waste. In lean manufacturing environments, product and process drive 80% of total costs, but the 20% that remains, largely in the production of product, can eliminate any false economies (un)realized with poor-quality, low-cost filtration solutions.
With this in mind, engineers require longer fluid life with cleaner fluid – it’s that simple. The aforementioned use-case is one of finishing, but it’s equally critical in painting, where the world’s most sophisticated – and efficient – processes paint shiny new cars, only to fail when filtration fails. This is a call to action.
As cost-sensitive purchasing teams seek quality filtration with lower-cost alternatives, standard-issue antagonists within the quality and consistency of the product always fail.
But why does cheap filtration fail? The answer lies in design shortcuts. Whereas Pall products lead the market in the proprietary design of innovative filter media, alternatives shortcut the following:
Filter Media. Demand fixed-pore filter media. In-use, filter fibers move, opening the pore structures, in turn releasing contaminants that, once captured, should be retained. The intersection of filter fibers should feature a fixed-pore structure, which will prove more efficient and reliable.
Tapered vs Uniform Pores. Unknown to many automotive engineers who procure filtration to ensure efficient and quality operations is the depth imperative at the pore level. Good filters are far from 2D ‘nets’ – they are three-dimensional traps, capturing contaminants as they move through the filter. Tapered pores enable a more effective filtration by adding depth.
Filter Construction. The worst filter scenario is bypass within the filter itself. That’s exactly what happens when filter quality is compromised in favor of lower cost. From quality filter media, to support, and even well designed drainage systems, construction and build represent nuanced and critical components of successful filtration. Design elements—such as epoxy-bonded end-caps—ensure structural integrity. Simply put, Pall provides complex, effective filter construction for superior results.
Fiber Size. Using smaller diameter fibers in the filter media is a critical component in designing the proper filtration solutions.
Good products not only contribute to efficient manufacturing of machinery, but they bring people together. And Pall products are critical in maintenance, product engineering and quality engineering alike.
Maintenance appreciates the durability – lower-cost solutions can require 300% or greater replacement time and expense in consistent use. Maintenance also appreciates the asset protection enabled by Pall – equipment, from manufacturing machinery to hydraulics, lasts longer with pall, saving operating expense and capital.
And engineers appreciate the quality and efficiency. In processes as seemingly simple as paint, defects can take 15 minutes to an hour to correct – a costly and unacceptable outcome in efficient manufacturing. But even more important than uptime is the delivery of quality products. And the production of quality products fundamentally requires maintaining operationally critical equipment with consistently clean fluids.