When auditing an installation, we look for solutions or alternatives to help our clients with 3 different aspects: Safety - Efficiency - Performance.
In the case of Garage mécanique Point S, our advice and changes were mainly focused on the energy efficiency aspect and performance.
CONTEXT OF THE CASE STUDY
Tire & General Auto Repair Shop
An industry veteran with over 20 years of experience in the automotive business, Patrick has relevant insights on the importance of compressed air. We met with him to discuss some of the challenges they face on a regular basis.
According to Patrick Bouliane, the compressed air network is the nervous system of Point S operations. Their priority is to ensure a good efficiency of the delivery of air to the tools because a lack of air has a negative impact on the efficiency of their operations. The lack
of power in their tools prevents the mechanics from being able to do their work on time.
“ In the tire business, there are two peak seasons where the appointments are stacked every minute of the day. During these periods, it is essential that our tools operate at full efficiency. The compressed air network is the lifeline of our operation and is in very high demand since all the tools must work at the same time. Air drops or insufficient air volume impairs tool performance. When a mechanic is faced with a jammed lug nut, a lack of air pressure prevents the tool from completing the task efficiently, resulting in slower productivity.
The nature of our business is about time efficiency and quality of the work. When a job takes longer than what we had scheduled, it produces a chain reaction that disrupts the entire schedule. The success of our company is directly related to respecting the schedule of appointments. The quality of our air tools and an efficient, reliable compressed air network are essential. We trust Topring because they have reliable solutions and high-quality products“.
General Manager, Point S Granby-Farnham
INCREASING TOOL PERFORMANCE AND EFFICIENCY
“ Topring was instrumental in identifying some key weaknesses in our compressed air network. They proposed simple relevant solutions that had an immediate impact on the performance of our tools. ” - P. Bouliane
Hose Length and Diameter
Hose length can be the biggest source of air loss in a compressed air network. If the hoses are too long or the diameter is too small, the volume of air cannot be optimal when reaching the service point or the actual tool.
Self-storing hoses are another cause of pressure loss due to air turbulence inside the hose. Choosing the right length/diameter combination yields the proper airflow which improves the efficiency of the tools.
Although air tool design can have a positive impact on the performance, it will never match the importance of the required air volume reaching the service point. A properly designed compressed air network will yield the volume of air required to maximize the operating efficiency of tools used
in these shops.
To maximize the volume of air delivered to the tool, the distance between the service point and the source of air must be kept to a minimum and the diameter of the hoses kept to a maximum.
By reference to the Topring chart on hose diameter evaluation, at least 1/2 ID hose is required to feed a 1/2 impact tool (28.6 SCFM).
“To increase the airflow volume we replaced all of the 3/8” self-storing air hoses and replaced them with 1/2” flexible hoses. We noticed an immediate increase in the performance of our tools. ” - P. Bouliane
|IMPACT GUN||FLOW SCFM||HOSE LENGTH (FEET)|
1/2 I.D. air hoses offer 2 times more flow than 3/8 I.D. hoses.
Hose reels not only increase efficiency but also provide an important safety component. When not in use, having hoses out of harm’s way creates a cleaner, safer work environment. Hose reels also protect the hoses and increase service life while decreasing maintenance costs.
“ We installed Topring hose reels at each service bay. It is much more ergonomic because the mechanics don’t have to handle the entire weight of the hose while working and it also creates a much safer work environment, reducing the clutter from the work stations. As a bonus, the reels greatly reduce the wear and tear on the actual hoses, reducing the direct contact with the ground. ” - P. Bouliane
High Flow Quick Couplers and Anti-Hose Whips
The diameter of the plug determines the volume of air (SCFM) that will flow through the air hose. To improve the efficiency of the air tool, a high flow coupler/plug combination must be used. Using a short anti-hose whip between the tool and the coupler will isolate the vibration from the coupler, extend its life, and reduce the chances of whipping.
Diameters of Each Plug Profile
“I replaced all of the existing couplers with Topring’s ULTRAFLO Safety Quick Couplers. They offer 80 SCFM and can handle 500 psi. This additional airflow increased the power of our service tools. I also added anti-hose whips the reduce vibrations. This had a significant and positive impact on the service life of our tools and couplers ”. - P. Bouliane
A real ROI
“These simple changes had a major impact on productivity during our peak seasons. Reducing down time because of underperforming tools, our technicians have been able to keep the jobs on schedule. In turn, this has enabled us to increase the number of appointments over previous years, which has increased profitability”. - P. Bouliane
MY EXPERIENCE WITH TOPRING
“Thanks to the compressed air know-how of the Topring team, I was able to put in place some simple, inexpensive solutions that had a major impact on our performance, in the shop and on the books. ” - P. Bouliane