Improving Plant Efficiencies and Carbon Impact at a UK MRF Facility: A Hoverdale Case Study on DRS Screening Shafts
The Challenge:
A UK-based recycling plant was reliant on OEM parts for their DRS Screen Shafts sourced from the USA, encountering substantial lead times of up to six months. This reliance severely hindered production efficiency due to delays in obtaining spare parts. The need to maintain a costly inventory of spare parts to mitigate the risk of downtime and the extended wait for new parts added financial strain. Additionally, frequent failures in the stub end shafts led to regular breakdowns, impacting production and profitability. This approach also contradicted the plant’s carbon reduction goals, as it involved significant carbon emissions associated with transatlantic shipping.
Customer Objectives:
– Decrease operational costs
– Shorten lead times for parts replacement
– Enhance part quality and reliability
– Minimise environmental impact
– Reduce dependency on large inventory holdings
The Hoverdale Solution:
Hoverdale conducted a thorough investigation to understand the high failure rate and rapid wear of the parts. Utilising insights from this analysis, Hoverdale re-engineered the shafts using a superior material designed to extend durability and prevent failures. The redesign process included designing and testing the new parts using Catia V6 3D CAD & Finite Element Analysis software.
The newly developed parts were field-tested, leading to significant improvements in performance and durability, greatly surpassing the original specifications. This innovation not only fulfilled the customer’s operational and environmental objectives but also set a new standard in parts sustainability and efficiency.
Results:
- 40% reduction in costs
- Lead-time reduction from 24 to 4 weeks
- Quality improvement increases service life and removes the design flaws causing catastrophic failures.
- Parts are manufactured in Warwickshire at Hoverdale Head Office, resulting in parts being within 30 minutes of the customer site.
- Hoverdale has sites located across the UK.
- Significant reduction in customer carbon footprint
- Customer no longer needs to hold large stock levels due to lead-time reduction.
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