Vapor Bus International
Buffalo Grove, Illinois
Intern: Patrick Ryan
University of Illinois at Urbana Champaign
Vapor Bus International specializes in the design and manufacturing of passenger door systems and related accessories for the transit bus industry, including windows ramps and lifts,. The Buffalo Grove manufacturing facility has over 100,000 square feet of manufacturing operations and warehouse space, with an additional 20,000 square feet of office space. The intern worked on a number of projects to conserve water, improve testing procedures and reduce energy usage.
Results:
The intern worked on the following projects and made the following recommendations:
- The revised the testing procedures for the chemical wash lines, and included pictures to to clarify certain work instructions. The intern devised a new test to be performed daily, which would allow calibration of the conductivity controllers automatically and remove the necessity for the operators to adjust the tank concentrations manually. This project has the potential to save $24,000 in preventative labor and rework due to poorly washed parts.
- The intern evaluated alternatives to the use of sulfuric acid and ferric sulfate to prepare aluminum surfaces for bonding using an epoxy adhesive. The alternatives include methacrylate products, which do not require extensive surface preparation. These alternative adhesives require additional performance testing but have the potential to save $10,000 annually.
- The ovens that cure a powder coat of paint on the aluminum and steel parts utilize air seals to contain the hot air inside the oven. These seals are serviced at the end of each summer, which means that hot air is lost during the summer months. The intern recommended that the tune ups be peformed at the start of summer. With the majority of heat loss occurring during the winter to the facility surroundings, this scheduling adjustment has the potential to save $7,000.
- The intern recommended that the lighting in the office areas be converted from 32Watt T-8 fluorescent light bulbs to 28W bulbs. Thhis project could save $2,000 a year.
- The intern recommended the use of a batch evaporator to reduce the volume of spent machining coolant. This project could save $1,000 a year in reduced disposal costs. The total estimated cost savings of the above projects is approximately $62,000 a year.
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