International Truck and Engine Corporation
Melrose Park, Illinois
Intern: Sam Bigger
University of Illinois at Chicago
International Truck and Engine Corporation manufacture a variety of diesel
engines. The facility sits on 70 acres, with manufacturing space of 1.5
million square feet. It currently employs about 600 people, with the
capacity to produce 85,000 engines per year.
The student focused on projects that included engine test cycle time, recycling,
and a closed loop water system.
Anticipated Results:
The intern made the following recommendations:
- Analyze the failed crankcase pressure and oil pressure engines and identify
the source of these failures to help reduce overall test cycle time.
- Move the leak test station to the end of the assembly line before the test
cells. This change will help identify porous cylinders,
which allow water to enter the system and mix with oil causing adverse effects
to engines.
- By reducing the test cycle time by three minutes can save over $120,000
a year on fuel costs, save $85,000 in reduced labor costs, and also reduce
air emissions.
- By implementing an expanded recycling program, the company will be able
to earn between $40-60 per ton on the sale of recyclable materials.
- The engine test cell area has a hot water closed-loop water system. By
insulating the water heater, pipes, and steam lines, the company can
save approximately $4,000 a year from reduced heat loss.
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