Innovative Parts Washing System

In 2008, Ford's engine plants began implementing the latest generation of an innovative new parts washing system developed in partnership with our supplier ABB Robotics. Ford began developing this technology with ABB in 1999, and began installing the current generation in our transmission plants in 2004. The new robotics-based system represents a significant leap forward in efficiency and environmental impacts. It reduces energy and water use, wastewater effluent requiring treatment and noise, all while significantly improving quality, flexibility, productivity and cost.

In the past, parts washing has required a significant amount of energy and water, and has produced large amounts of wastewater requiring chemical treatment. The previous systems also took up a lot of floor space and were complex, unreliable and inflexible.

The new system cuts energy consumption by approximately 60 percent and energy costs by 90 percent. Part of this energy reduction comes from the fact that, unlike previous systems, the new system does not require any heat. It also requires a much smaller water pump, further reducing energy usage.

The robotic parts washing system also uses water more efficiently. It reduces wastewater generation by 95 percent compared to previous systems, which removed dirt chemically by spraying parts with high volumes of water and detergent at low pressure. This system, in contrast, cleans parts mechanically using very low water flow. The system uses a robotic arm to move the part in front of the spray nozzles, so it cleans parts more effectively. It uses approximately 10 to 15 gallons per minute of water, compared hundreds of gallons per minute with the previous system. Eliminating detergents also allows us to reuse the same wash water more times. The system uses smaller water tanks and low flow to further increase the efficiency of water use. In addition, the system generates little to no oily waste, which would require process waste treatment. It requires only a small amount of rust-preventive solution for cast iron parts or aluminum parts with powdered metal inserts.

The new system also improves exhaust emissions. Past systems, which required the use of detergent, emitted water vapor that contained some detergent. The improved system exhausts only water vapor.

In addition to these environmental benefits, the system improves the cleanliness of the parts by an order of magnitude, reducing the amount of residual contaminants by more than 70 percent. The new system increases productivity by facilitating the use of multiple washing units in parallel and reducing maintenance downtime. It also improves working conditions due to its reduced complexity, compact layout, inherently improved reliability and best-in-class noise levels.

We have already installed 34 of these new robotic washing machines. We have also incorporated this technology as standard for all engine and transmission final wash applications, ensuring that these improvements will be realized by all future vehicle programs.