A stamping plant was experiencing excessive downtime due to the overly smooth grinding of a roll used in the process. The grinding not only caused significant machine downtime but also left grit residue, damaging the metal sheets as they passed through, leading to increased scrap and roll replacements.

Martin conducted a thorough evaluation of the process. After several tests, the team identified a specialized Scotch-Brite pad that could achieve the desired surface finish more efficiently and at a higher quality than traditional grinding.

The implementation of the new pads resulted in the following benefits:

• Reduced weekly downtime from 8 hours to 4, resulting in an annual up-time savings of $1,580,800.
• Eliminated residue on the rolls, significantly reducing the need for costly $10,000 roll replacements.
• Achieved the ideal surface finish, reducing defects and scrap while enhancing the quality of metal sheets produced.

Dramatic Reduction in Downtime: Martin’s solution cut weekly downtime from 8 hours to 4, resulting in an impressive annual savings of $1,580,800 by increasing machine up-time.

Lower Maintenance Costs: The specialized Scotch-Brite pads prevented grit residue buildup, significantly reducing the need for $10,000 roll replacements, leading to long-term cost savings.

Enhanced Product Quality: By achieving the ideal surface finish with the new pads, the operation experienced fewer defects, reducing scrap and enhancing the quality of metal sheets produced.