CASE STUDY 2
Unlocking Efficiency in Automotive Manufacturing:
Reducing Mold Release Agent Consumption by 20% and Saving $40,000 USD Annually
Challenge
IAC Toluca faced excessive mold release agent consumption in the production of headliners. The existing product’s inefficiency led to higher costs and reduced productivity.
Results
- Reduced mold release agent consumption by 20%.
- Increased production output by 16 additional headliner pieces per shift.
- Achieved annual savings of $40,000 USD.
Solution
Intermol 505, a semi-permanent water-based release agent, was introduced. Combined with a new atomized application system, it improved efficiency and minimized waste.
Impact
Improved cost-efficiency and production capacity.
Volkswagen (Mexico)
Achieved a 20% noise reduction and enhanced compliance with OEM standards through InterMotive OPF 526.
KIPP Car Comfort Systems (Brazil)
Cut lubricant consumption by 15% and logistics costs by 50% with InterMotive GPX 201.
Acumuladores Moura (Brazil)
Streamlined lead casting processes with Intercad TF Spray, eliminating mold lock-ups, reducing spray consumption by 288 cans annually, and boosting productivity by 20%.
GDBR (Brazil)
Improved microwave conveyor bearing efficiency with Interplex 1500 2, reducing lubricant consumption by 50 kg annually and extending relubrication intervals from 120 to 720 hours.
VW MAN (Brazil)
Optimized truck engine assembly with InterMotive DE 205, reducing lubricant consumption by 119 liters annually and achieving annual savings of R$30,004.70.
Sogefi Engine Systems (Mexico)
Enhanced production reliability with InterMotive GHC 501, passing critical sealing tests, resisting extreme conditions, and supporting annual output of over 40,000 units.
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