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Optimising production line maintenance for gas burners

Whenever flow of gases needs to be adjusted or monitored, KOBOLD's model UTS, a practical and affordable variable area flowmeter for monitoring gas burners. This compact measuring instrument can be placed at various locations, precisely where required.  Recently the company was tasked with optimising gas burner production line monitoring in order to achieve a ‘No Product Rejection’ status.

The Task
Lighting machine manufacturers generally require several small and one large annual maintenance sessions on their production lines. This means shutting down (completely dismantling) the production lines.  All failures to be fixed, broken or worn parts replaced, burners and valves refurbished and production lines reassembled.
It is only after such maintenance, that production restarts.  Each production phase of the renewed line must be re-synced, each burner reset at the correct temperature and the entire production process adjusted in order to manufacture the highest quality product. This requires not only precision but is time-consuming and involves a significant quantity of reject products. The time consumed and the wasted goods cost money, increasing the final product cost and, also may result in a serious competitive disadvantage in the market.

The Kobold UTS solution:

Production lines are equipped with the Kobold UTS type variable area flow meters.  One Kobold UTS is built into each gas circuit for gas burner control. Retrofitting of machines without major modification even with 10-20 flow meters is easy due to the Kobold UTS’s compact design and small footprint. When the production line produces a perfect product, the displayed values of the instruments are recorded. Following the next shutdown of production lines and before starting the conveyor-belt, all burners are set up to the value recorded by the Kobold UTS. It takes only a few seconds to then set each burner. Users could re-start continuous production in a short time, as the quality of the first finished product will be perfect. The total investment is returned after only a few maintenance cycles.  Typical examples include monitoring supply to gas burners or engines and the supply of laboratory equipment with different gases.

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