Quaker Management Services Manual
The Quaker Management Services Concept is based on a focus on core competencies
of both Quaker and our Customer to achieve optimal mutual performance.
Section 1. Program Overview
Today’s
competitive markets require manufacturing companies like yours to continuously
see improvements in your processes by raising productivity; lowering
costs; and maximizing efficiency; to generate more income from your business.
We can help you meet these objectives by providing the following functional
services.
- Inventory Control
- Product Specification and Selection
- Process and Application Expertise
- Preventive Maintenance Support
- Continuous Improvement Projects
- Health and Safety Support and Training
- Environmental Compliance &
Waste Management
- Data & Information Management
- Communication Program
- Laboratory Analysis
Quaker provides the following features in a phased implementation method that ensures an effective Management Services Program.
- A three-phased approach to implementation can be used to smooth
the transition to Chemical Management.
- Quaker provides research and development support and new product
technology to keep your plant on the cutting edge of new products and
applications.
- ChemTRAQ® can be used to provide environmental management system
support.
- Technical service and support, chemical materials in all wet process
areas.
- Quality verification on all incoming materials included in the program.
- Statistical Process Controls (SPC) for applicable process areas.
- Consolidation of chemical products, drum reduction, and usage reduction
through process control and recycling measures.
- State-of-the art Inventory Control
System including bar coding and JIT delivery.
- Process evaluations and recommendations for continuous process improvement.
- Training plant personnel on proper and safe use of chemicals.
- Participation by Quaker staff in committee meetings to maintain communications.
- Quality assured by our ISO 9001 certification.
The purpose of this program is to provide an efficient, cost effective solution to chemical usage throughout your plant. The goal is to manage all chemicals used in your plant. It is not our intent to change any chemicals or products that perform to specifications and are achieving the best cost and performance possible. The following is a description of
typical comprehensive Management Services program.
Section 2. Inventory Control
By
purchasing the right amount of needed chemicals and assuring timely delivery
at the point
of use, the impact of chemical use on production is minimized. In Phase
II of the Program, Quaker will provide a state-of-the-art inventory control
system.
Product Receiving and Inventory Control
Quaker will manage the scheduling of material to ensure the availability
of the chemicals to meet the plant's production needs. Data will be generated
to determine the appropriate max/min order points that will optimize
inventory control, as well as, product delivery costs. It is Quaker's
intent to optimize freight costs in conjunction with speed of delivery
and reliability. We will institute a policy of drum reduction, as well
as, bulk delivery of some items. Where acceptable, a bulk-to-bin delivery
system will be implemented. This will allow for substantial savings in
product price and container handling. Additionally, a bulk-to-bin system
frees up floor space and incorporates a disbursement site.
Disbursement sites will enable the Management Team to maintain accurate
usage documentation for each burden or cost center.
The Quaker Program Manager will be responsible for inventory control,
ordering, warehousing, and delivery of all products covered by the Management
Services contract. Deliveries will be scheduled to meet the plant's requirements
and made in a JIT manner to keep on-site inventories at a minimum. Delivery
times will be arranged with the Shipping/Receiving Supervisor. Advanced
approval will be obtained for deviations from the agreed upon schedule.
Products not manufactured by Quaker will be purchased by Quaker's Management
Team on a second- and third-tier basis. The plant will realize a number
of benefits from Quaker’s inventory system including the following:
- Labor and cost savings - reduced record keeping and interface with suppliers
- Product inventory is assured; out of stocks are avoided
- Quaker Chemical owns the inventory eliminating the cost of inventory for the plant
- Fewer purchase orders generated
- Fewer invoices generated
- Assurance of full compliance with Local, State, and Federal Guidelines
- Ability to immediately locate specific chemicals
- Reporting of chemical usage by specific burden or cost center
- JIT inventory control
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Section 3. Chemical Product
Specification and Selection
Performance and price. Two elements
that inevitably go hand in hand. Our major objective is to relate the
two in ways that assure clearly measurable benefits. We quantify the
total cost of using chemicals.
Understanding and Accounting for All Chemical-Related Costs:
In most manufacturing plants, attention is focused on the unit cost of chemicals: emphasizing bulk purchases, package size, grades of material, and inventory levels. In our Management Services Program, we determine the total impact on your operation of using various chemicals. We identify the following hidden costs:
- Acquisition
- Ownership
- Delivery
- Receiving, Handling and Storage
- Application and Use
- Disposal and Recycling
- Compliance with Regulations
We also look at indirect impacts of the chemical used that impact your profitability including:
- Production Rate
- Tooling Life
- Quality
- Waste Part Production
- Employee Productivity and Health
- Upstream and Downstream Process Impacts
As with all fields today, technology is moving ahead at an increasing pace. We at Quaker are continually searching the world for new concepts and products from our organization and from sources outside of our company. Our success depends on our ability to do this and to determine the optimal use of the various technologies by our customers. Our objective is to identify chemical specialties that are clearly superior to current products, and incorporate them in a unique offer of teamwork, service, application know-how and support that provides you with the optimal cost/performance ratio.
We do this by maintaining long-term relationships with other chemical
suppliers with whom we team, and by cooperating with competing companies
who may have a superior product for a specific application. If the results
we desire cannot be achieved using conventional products, we are prepared
to develop custom-formulated products. Our R&D process involves
our specialists interacting closely with your process experts to gain
insight into the fluid-process interaction which then enables us to formulate
the products needed.
Section 4. Chemical Product
Use and Control
The proper use of chemicals in your plant requires
ongoing monitoring and control. Quaker’s product knowledge base
and analytical capabilities assure that our on-site staff provides you
with world class, real-time problem resolution and process optimization.
On-site Laboratory
Quaker will manage and operate a full-time, on-site laboratory for
the prompt evaluation of metalworking fluids. The requirements for this
facility will be identified and described in the program Scope of Work.
Quaker will provide any necessary equipment or laboratory glassware
required for the program up to an agreed cost. Quaker’s Corporate
Analytical Laboratory is dedicated to the support of all off-site Management
Services laboratories.
Central Analytical Laboratory
The Quaker Analytical Lab, located in Conshohocken, Pennsylvania is
a state-of-the-art support laboratory servicing Quaker’s Management
Services Partners in terms of the development, manufacture and application
of high quality products. Although the bulk of the service is provided
to our North American customers, the support required by our worldwide
affiliates and subsidiaries gives the Analytical Laboratory a global
view of technology and its progression. As part of Phase II of the
program, the plant will have access to the support and expertise of
this laboratory.
Quaker Product and Process
Immediate access to Quaker’s global technical knowledge is provided by our internal communication and data management systems. This system includes a global electronic communications system. Using this communication system, information is transmitted to and from any Quaker location in the world. A network of the people providing management services at customers’ plants receive periodic communications on best practices on a global basis.
All products produced by Quaker have a knowledge base of actual applications where the chemical is used, including performance characteristics and process problems that have been experienced. Finally, individual technical experts are dedicated full-time on a global basis to achieve technology transfer.
Systematic Process Evaluation
In optimizing the application of products we combine your knowledge of your plant and processes with our product knowledge and system-wide view. By looking at upstream and downstream processes, and even suppliers’ and customers’ processes, an overall systems view is achieved that enhances your production efficiency.
Section 5. Preventive Maintenance
Lubrication Program
"An ounce of prevention is worth a pound of cure" is no more
true anywhere than in manufacturing plants. Monitoring maintenance lubricants
allows Quaker to identify where problems exist, and help lubricant suppliers
apply state of the art management systems.
At the core of Quaker’s Preventive Maintenance Lubrication
Program are six tasks:
- Understanding
- Specifying
- Monitoring
- Detecting
- Correcting
- Avoiding
Understanding involves the training of Management Services and plant personnel in all aspects of lube oil and grease physical and chemical characteristics, including additive technology.
Specifying includes the development of lube charts for critical and common machinery for process optimization and product consolidation. We survey existing vendors for new and promising additive technology to focus on downtime avoidance and cost reduction.
Monitoring of lubricant product and process conditions provides the data needed to anticipate and avoid maintenance failures. Detailed documentation allows trend and follow-up analysis to pinpoint causes of failures and modify procedures to avoid future occurrences.
Detecting is the process of learning to correlate knowledge of process, lubricants, environment and application to separate cause from symptom. Quaker will work together with the plant to enhance current maintenance lubricant detection techniques.
Correcting maintenance lubrication problems is the primary focus for cost reduction and downtime avoidance.
Avoidance of downtime and repair costs is the primary goal of a Preventive Maintenance Program. Improvement in these items is the metric we use to measure success of this program.
A firm grasp of these tasks is essential to a World Class
PM Program. The major elements of this program to achieve the above
goals include:
- Routine Oil Analysis
- Temperature Monitoring
- Vibration Monitoring
- System Inspection
- Ferrography
- Lubricant Charting
- Bar Code Leak Quantification
Section 6. Continuous Improvement
Quaker
is committed to consistently supplying our customers with products and
services of outstanding quality and performance. To do this we must continually
prove our value, and maintain a high level of customer confidence.
Continuous
improvement in our Management Services' programs is the centerpiece of
Quaker’s value to the customer. Our continuous improvement program
deals with those factors that reduce manufacturing costs and increase
productivity. Although it takes more time to achieve the process and
production improvements in this area, the impact on the cost and profitability
of the plant is many times greater than those achieved through purchasing
and price reduction. Our Management Services Partnership develops the
atmosphere where all parties work together in a mutually beneficial way
to improve plant performance. Focus on results is the key to enhancing
performance and reducing overall costs. This requires active participation
from Tier II suppliers, outside specialists, consultants, and plant employees.
Quaker provides the systems and focus to do this.
During Phase II of the Partnership, the Quaker Team will maintain a daily tour of all operations pertaining to the program and will physically inspect the mechanical operations, as well as, the chemical condition of washers, coolant systems, and all applicable lubrication equipment.
This Program Includes:
- Interaction with operators and plant personnel.
- Documentation and resolution of questions and concerns
relating to employee health and safety.
- Troubleshooting chemical-related problems.
- Identifying areas in need of improvement.
- Documenting areas that appear "out-of-spec."
- Clean-out procedures (and frequencies) will be reviewed
to ensure production of quality parts.
The Quaker Management Services (QMSsm) Team will thus be able to address abnormal conditions, problems, concerns, and generate predictive and preventive maintenance techniques that will enhance the baseline data for continuous performance improvement.
Documentation and Reporting
Continuous improvement depends on constant monitoring and reporting
of process conditions and establishing baseline operating conditions.
Quaker employs Program Management Software and databases that we have
specifically developed for reporting and documentation in Management
Service accounts. This software actually models the manufacturing facility
on a machine by machine basis to allow analysis of individual machines
or entire operations. Documentation assures accountability and identification
of remedial actions necessary to maintain proper performance.
Section 7. Safety, Health, & Environmental
Compliance
Care for the environment is an ever more demanding issue. Quaker
believes that every effort must be made to avoid harm to the environment
and to contribute to solutions that help sustain the quality of our surroundings.
ChemTRAQ®
ChemTRAQ® is an environmental management software package that
uses data about hazardous materials used in your plant to help meet
EPA and OHSA requirements. ChemTRAQ® focuses on Hazardous Communication
standards and EPCRA reporting requirements. The software allows you to
print important documents like material safety data sheets, safe use
instructions, and chemical inventory lists. ChemTRAQ® can also assist
in filling out reports like Form R and Tier I & II required yearly
by the EPA and OSHA, either manually or using data directly from Image
inventory control software. ChemTRAQ® was developed to help minimize
the time required to meet EPA and OSHA Hazcom standards. ChemTRAQ® will
provide the plant with convenient MSDS management and environmental reporting.
The software manages the information from process surveys including
Quaker metalworking, cleaning, corrosion prevention, and stamping/forming
surveys. The equipment and process data is stored to facilitate chemical
control, data management, conversion information, hazardous communication,
training, OSHA auditing, The data supports the storing and printing of
Safe Use Instructions and warning signs for posting at machine locations.
Reports Generated:
- AHH (Additional Health Hazard) Report
- Chemical Characteristic Report
- CAS # Report
- Warning Sign Inspection Report
- Audit Report
- Chemical Posting Report
- Product Line Report
- Department Report
- Equipment Report
- Equipment Location Report
- MSDS Date Report
- MSDS Date Audit Report
Section 8. Recycling/Reclamation
Recycling
of process chemicals reduces your costs as well as improves the environment.
Through our program we integrate product selection, process application
and recycling needs to achieve the optimum performance and lowest cost
of the chemicals you use.
Recycling is an integral part of the majority
of our Management Service Programs. The goal of overall cost reduction
will be greatly impacted by on-site recycling. This concept will be aggressively
pursued by Quaker in Phase II. We propose the implementation of a program
that will significantly reduce chemical disposal with the eventual goal
of zero discharge of spent or contaminated metalworking fluids.
Currently, we are working with several companies in multiple locations
to recycle products rather than dispose of them. Based on the plants
that are being serviced, we have been able to enhance their production
and show substantial cost savings.
The following lists the areas in which we have achieved substantial savings:
- Hazardous Waste Disposal
- Waste Treatment
- Chemical Usage
- System Longevity
- Tool Life
- Surface Finishes
- Operator Acceptance
- Chemical Additives
- Housekeeping
Section 9. Communications, Training & Program
Structure
Communication is the lifeblood of any World Class Management
Services program. Quaker ensures the accurate and timely transfer of
information through:
- Attendance by Quaker site team members at all scheduled program
review meetings, emergency meetings, and audits.
- Interaction between Quaker's on-site Management Services Team and the plant’s personnel on a daily basis.
- A dedicated effort for clear understanding of each person's role and responsibilities
to the customer’s Management Services Team.
- Active participation by Quaker team members on committees and involvement with
the plant's environmental, health and safety, maintenance, operators, foremen, and department personnel.
- A willingness to attend departmental meetings and address employee concerns.
- Publishing the names and materials of any subcontractors providing material to the
plant under the terms of the Management Services Agreement.
- Quaker long-term relationships with second tier suppliers, consultants, specialists, trade organizations, and machine tool manufacturers.
- Twenty-four hour availability of Quaker site personnel through pagers and an emergency phone list on file with the plant.
Scope of Work
To assure that expectations are clear, and the services to be provided under this program are defined, a scope of work will be prepared and included as part of the final contract. This scope typically includes changes to the original concept based on detailed information obtained during Phase I of the program.
Training
For a partnership like this to work, everyone must realize the importance of the chemicals they are using and how to use them. Quaker will custom design a training program to work in conjunction with the plant and their accredited programs. The following will illustrate each training program and the topics that will be discussed.
A. Chemical Management
B. Regulatory Awareness
C. System Maintenance
Advanced training will be given to personnel in machine and system maintenance. These areas of training will include: Machine clean out procedures, quality control processes and chemical disposal.
If you would like to learn more about Quaker's Management Services (QMSsm), please contact us at: info@quakerchem.com
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