Type of Loss:
A fire started on an idled 3,000 Ton Injection Molding Machine during the third shift of a tier one automotive supplier. First responders were able to extinguish the machine fire before it spread in the plant. However, the machine was considered a loss and 50,000 sq. ft. of automated assembly area was covered in highly corrosive soot.
Challenges to Overcome:
- The customer was on a “just in time (JIT) delivery schedule” with several automotive assembly plants and had to resume critical operations in 12 hours. Shutting down was not an option for them as they supplied a large automotive manufacturing plant.
- The fire occurred on a Friday morning at 1:00 a.m. and all 40+ automated work cell (Machines) had to be operational by the start of first shift Monday morning.
- The 3,000 ton injection molding machine had only one back-up machine at the plant and had to be replaced or repaired in 16 weeks. Considering cost and time, a rebuild by the ERS team was the only option for the injection molding machine. If the plant wanted to purchase a new machine it would have cost a million dollars with a delivery schedule of 42 weeks….unacceptable.
- The OEM would not rebuild the existing machine on site and warranted it considering all the fire damage.
- ERS, Inc. mobilized over 30 technicians and immediately started to clean and restore the following critical pieces of equipment for production due in 12 hours.
- 3,000 ton injection molding machine adjacent to the fire damaged one.
- Two Fanuc robots and unload conveyor.
- Four door panel assembly lines (including 12 automated assembly machines).
- Worked with Cause and Origin Engineering Investigators to preserve a suspect area of the machine and facilitated the removal of the machine to their site for evaluation.
- ERS developed a strategic plan to rebuild 3,000 ton machine and two FANUC robots on site within the required time frame.
- ERS met ALL critical production start-up deadlines for the customer.
- ERS restored the fire damaged machines to better than pre-loss condition using the latest in controls technology within the required time frame.
- Total restoration of the 3,000 ton injection molding machine and two FANUC robots was less than 20% of new and included a one-year warranty on parts and labor.