Worksite Improvement Case Studies

The Pharmaceutical, Cosmetic and Chemical Workplace

Less odor transferred to hoses, less liquid pooling in couplings, and increased work productivity!

Silicone hoses fastened with hose clamps were being used to transfer products and clean with alcohol during cosmetics filling processes. However, these silicone hoses were being replaced once every six months, due to concerns about odors coming from them. There were also sanitary concerns due to liquid pooling, so employees had been disassembling and cleaning hoses every day. This created a lot of extra work.

During tank interior steam washing, cracked hose sheath fragments may fall into the tank, causing foreign matter contamination

Tanks of raw material for cosmetics are regularly washed with steam, but just two to three months of use causes the steam hose sheath to crack. Measures were required for the risk of contamination with foreign matter due to small fragments of rubber from the cracked hose falling into the tank.

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The Semiconductor and Precision Instrument Workplace

Noise and coupling disconnection caused by vibration eliminated

It was very noisy in factories due to piping vibration.
Also, sometimes the arm type coupling’s arm disengaged due to vibration, causing fluid leaks and disconnected fittings that required tiresome cleanup. In severe cases the couplings were damaged.

Damage avoided by preventing incidents caused by hose coupling leaks and disconnections

A PVC hose had been connected with a cap nut coupling, for use as a pipe carrying coolant for a system used to manufacture precision parts. However, fluid began leaking from the hose connector. In addition to stopping the manufacturing system, damage caused by leaking fluid resulted in massive damage to the line (which operated 24 hours a day, 365 days a year). Urgent measures were required.

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Factory Equipment Hose Examples

Reduced hose degradation and improved production by increasing heat resistance, and increased efficiency by reducing how frequently a part must be replaced

The customer had been using a suction hose to transport plastic pellets for parts at an automotive parts plant. However, the temperature would rise to around 80°C during use, even though the hose had a heat resistance of only 50 to 60°C. The customer was suspicious of the ability of the hose to resist that much heat. This actually had caused the hose to degrade rapidly, and it often had to be replaced, reducing efficiency. Something had to be done.

Resolved trouble caused by a hose disconnecting from a metal temperature controller, and significantly improved productivity!

The customer was using a tube clamped with a competitor’s coupling for piping carrying recirculated water for cooling, connected to a metal temperature controller. The coolant traveling through the piping had a pressure of 0.6 Mpa, but the tube became disconnected from the coupling, causing flooding in the plant. Production had to be stopped, while subsequent cleanup and drying took some time to complete, resulting in production loss.

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The Plastic Molding Workplace

Improved antistatic design shortens cleaning times for greater work efficiency

A suction hose was used to transport plastic pellets to molding machinery.
Static electricity was generated during operation, which caused pellets to block the hose, disrupting production. Because the hose was opaque, it was difficult to tell where the blockage occurred. Locating the blockage took time, which made production less efficient.

Significantly increased productivity and safety by preventing hose degradation and coupling disconnection/leakage.

The customer was using a heat-resistant silicone hose connected with a barb hose clamp to transport hot water (120°C) for a plastic molding machine. However, the hose began to crack in less than one year of installation, and issues such as coupling disconnection and leaks were also occurring. The customer needed to do something to prevent production loss and work injuries caused by burns.

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The Machinery Manufacturing Workplace

Eliminated oil leaks caused by steel piping cracks caused by vibration, and made site operations easier

The customer was using metal piping as drain piping for cooling a crane used to transport parcels. However, vibration caused by the crane moving created stress fractures in the metal piping, causing frequent oil fluid leaks that worsened the appearance of the crane.

An over-tightened clamp cuts the hose, resulting in a water leak

A clamp had been over-tightened at a plant, cutting into the hose and causing a water leak. When they moved into a new plant, there was electrical wiring near the location of the leak, so they needed to rethink their entire hose piping configuration.

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The Food and Beverage Workplace

Issues caused by clamps were eliminated, enabling stable production

A factory that produces food products uses hoses in various areas, such as production lines. All of these were assembled with barb fittings and fastened with clamps.
There was an incident where the tip of a worker’s glove got shredded while the worker was fastening a clamp, and the pieces ended up in products. The problem was detected and averted before the products were shipped, but we designed clampless hoses to solve this issue in future.

Reduced time spent cleaning hoses, and increased both work efficiency and productivity

The customer was using PVC spring hoses as air piping in a plant manufacturing secondary processed Japanese tea products. However, powdered tea leaves would be carried through the air in the plant and become attached to the insides and outsides of the hoses. The customer needed to completely clean any powdered tea leaves stuck to hoses to maintain hygiene, and doing so required stopping the entire line. Cleaning would take 30 minutes each time.

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