Company Overview
Altex Corporation, a member of the Toyota Industries Group, specializes in manufacturing aluminum die-cast products for automotive compressors. The company has built an integrated production system spanning from casting to machining and inspection, delivering stable product supply under high-precision quality control.
As environmental demands in the automotive industry continue to grow, Altex is driving company-wide energy savings and carbon neutrality initiatives, with improving energy efficiency in manufacturing processes identified as a key management priority.
Background of Adoption
With energy savings and carbon neutrality set as management targets, reducing energy costs related to compressed air became a major theme for Altex. Compressor electricity consumption represents a significant portion of overall usage, making air leak loss reduction an urgent priority.
Through a business partner referral, they learned about AirMore's acoustic air leak visualization camera. The ability to confirm in real-time even fine leaks that were difficult to detect with conventional methods was highly appealing, leading to the adoption decision.
Product Adopted
The product adopted was the CRY SOUND 2620 acoustic camera. Its key feature is the ability to visualize air leak locations in real time, even while equipment is operating.
Conventional methods using listening rods or soapy water required equipment shutdown, but with the CRY SOUND 2620, leak locations can be identified without stopping production lines. This convenience was the decisive factor in the adoption.
Previous Approach
Before camera adoption, the response to air leaks was essentially reactive. Repairs were centered on addressing visible large leaks or when equipment stopped or broke down, with no planned leak countermeasures in place.
While some checks were conducted during scheduled equipment shutdowns, it was impossible to inspect all piping within the limited time available. Many minor leaks continued to be overlooked, resulting in energy costs accumulating unnoticed.
Current Usage
Currently, air leak visualization camera inspections have been incorporated into the monthly TPM (Total Productive Maintenance) activities. Leak locations detected by the camera are listed, and repair schedules are reflected in the following month's maintenance plan, establishing a systematic operational cycle.
This system has formalized the process from detection to repair, breaking free from reliance on individual expertise. Because any on-site team member can easily operate the camera to find leaks, compatibility with participatory maintenance activities has been rated very highly.
Results
During the first TPM activity after adoption, numerous previously unrecognized minor air leaks were detected, with 5-6 leak locations repaired. Even leaks at levels extremely difficult to find with conventional methods were accurately captured by the camera's high-sensitivity acoustic detection capabilities.
Inspection time has also been significantly reduced. What previously required applying soapy water and checking each location individually can now be scanned across wide areas in a short time using the camera, dramatically improving work efficiency.
Additionally, during the repair process, equipment malfunctions caused by air leaks were also discovered. There were cases where pressure drops from leaks had been causing equipment operational failures, revealing that air leak countermeasures also contribute to stable equipment operation.
The estimated annual savings are approximately 3 million yen, representing a very high return on investment. Altex plans to continue implementing ongoing air leak countermeasures in conjunction with TPM activities, aiming for further expansion of energy savings.