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‍A facility faced a critical failure in their rubber mill, a 100-year-old machine manufactured in the 1920s. The failure was caused by a bad bearing which resulted in significant damage to one of the shafts and the brass lining. All Enterprises Inc. was brought in to provide a comprehensive repair solution to restore the machine's functionality and prevent future failures.

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Challenges

• Old and Damaged Equipment: The rubber mill, being over a century old, had seen numerous repairs over the years, including a spray weld done 40 years ago. The current failure required precise machining and innovative solutions to avoid repeating temporary fixes.
• Tapered Shaft and Bearing Issues: The shaft where the bearings go was tapered, adding complexity to the repair. The previous spray weld repair was extensively damaged, making it unsuitable for another spray weld or chrome fix.
• In-house Machining and Sleeving: The repair involved turning down the shaft and pressing a sleeve on it, shrunk by 150 thousandths to ensure it would not come off, avoiding any temporary fixes like spray metal or chrome.
• Multiple Clearances and Damaged Parts: Multiple clearances needed to be accommodated for new bearings, and extensive damage to the brass pieces required in-house braze welding and thrust bearing repairs.
• Coordination and Timeline: The facility ran 24/7 and needed a quick turnaround to avoid prolonged downtime. All repairs had to be completed within three weeks to minimize the impact on the facility's operations.

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Innovative Solutions

All Enterprises Inc. employed a strategic approach to address these challenges effectively:

• Shaft Repair and Sleeving: Using an in-house lathe, we turned down the end of the shaft and pressed a metal sleeve on it, ensuring a permanent fix without the risk of future failures.
• In-house Machining and Welding: All damaged parts, including the brass pieces, were repaired in-house. We braze welded a thrust bearing and manufactured new bronze piston rings to seal the oil, replacing the damaged ones.
• Precision Machining and Chroming: The inner dimension of the shaft was machined and chromed to build up what was removed, followed by ID grinding to achieve the correct size. Two gears were also repaired and reinstalled on the shaft.
• Comprehensive Planning and Coordination: We developed a detailed game plan, identified all damaged parts, and utilized old drawings to ensure the repairs met the required tolerances and clearances. The entire process was coordinated to ensure a quick turnaround and successful outcome.

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Project Outcome

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The project was completed within the tight three-week timeline, significantly faster than the months it would have taken other companies relying on outsourced repairs. All Enterprises Inc. demonstrated their capability to handle complex repairs with in-house expertise and equipment, ensuring a seamless and durable solution for the client. The machine continues to run effectively seven years after the repair.

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Key Highlights

• Project Complexity: Tackled a 100-year-old machine with outdated drawings and numerous previous repairs, requiring precise machining and innovative solutions.
• Cost-Effective Solution: Provided a permanent fix with in-house machining and sleeving, avoiding temporary solutions like spray metal or chrome.
• Efficiency: Completed the project within a critical three-week timeline, minimizing downtime for the facility.
• Expertise: Extensive experience in handling similar failures and providing comprehensive repair solutions, including mechanical, rigging, machining, and coordination.

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For more information or to discuss how All Enterprises Inc. can assist with your complex machinery repairs and maintenance needs, please contact us.

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‍All Enterprises Inc. was tasked with the challenging project of restoring a severely damaged screw press at a facility in San Diego. The machine had been out of operation for three years, with multiple mechanical contractors unsuccessfully attempting to repair it. All Enterprises Inc. took on the project with the determination to get it operational.

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Challenges

• Initial Condition and Previous Attempts: The screw press had been damaged for three years, with multiple mechanical contractors unable to repair it, leading to the machine being repeatedly disassembled and reassembled without success.
• Complexity of the Press: The press featured a flywheel assembly that required removal through the facility's roof, necessitating coordination with the FAA and local authorities for crane operation, permits, and logistics due to the facility's proximity to an airport.
• Damaged Components and Design Flaws: All Enterprises Inc. discovered that a previous repair attempt had further damaged the press, including a faulty bearing and a flawed original factory design that prevented the press from functioning correctly.

Innovative Solutions

In-depth Diagnosis and Modification: Through careful analysis, All Enterprises Inc. identified that the original design of the press was flawed, particularly with the bearing arrangement. The team modified the press by adding an additional bearing to ensure proper alignment and functionality, addressing the core issue that had eluded previous repair attempts.

• Precision Machining and Custom Fabrication: All Enterprises Inc. removed the press and transported it to their facility for detailed machining and part repair. This included custom fabricating a new bearing arrangement, modifying the shaft with heat-treated material, and making new bronze oil seals and lock nuts, all of which were critical to the machine's operation.
• Expedited Supply Chain Management: The bearings required for the repair were metric and had a 12-month lead time from the official supplier. Leveraging decades-long relationships with vendors, All Enterprises Inc. sourced the bearings in just two weeks, significantly reducing the project's timeline.

Project Outcome

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The screw press was successfully restored to full operational capacity and has been in service since 2017 without any issues. All Enterprises Inc.'s modifications not only fixed the immediate problems but also enhanced the machine's longevity by incorporating modern materials and design improvements.

Key Highlights

• Restoration Success: Overcame the challenges of previous failed repairs and restored a screw press that had been out of operation for three years.
• Design Improvement: Identified and corrected a fundamental design flaw by adding an additional bearing, which has kept the press operational since the repair.
• Vendor Relationships: Expedited the procurement of critical components, reducing lead times from 12 months to two weeks.
• Precision and Expertise: Demonstrated expert-level precision in machining, custom fabrication, and assembly, ensuring the machine's long-term functionality.

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For more information or to discuss how All Enterprises Inc. can assist with your machinery repair and rebuild needs, please contact us.

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A facility experienced a devastating fire that caused extensive damage to their equipment, including their presses. All Enterprises Inc. was tasked by the insurance company to rebuild all of their presses, ensuring they were restored to full operational capacity.

Challenges

1. Extensive Fire Damage: The fire caused significant damage to the presses, requiring a comprehensive rebuild of various components to restore functionality.
2. Precision and Accuracy: Rebuilding the presses involved precise machining and fabrication to ensure all parts met the required specifications for effective operation.

Innovative Solutions

All Enterprises Inc. employed a strategic approach to address these challenges effectively:

1. Fabrication of New Components: New tie rods and tie rod nuts were fabricated to exact specifications for reliable performance.
2. Machining and Resurfacing: All platens were faced, and the tie rod holes were re-bored to restore them to their original condition. Every surface was meticulously machined to ensure proper alignment and operation.
3. Comprehensive Rebuild: Each damaged component was either repaired or replaced, ensuring the presses were fully restored to their pre-fire condition.

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Project Outcome

The project was completed successfully, with all presses rebuilt and restored to full operational capacity. All Enterprises Inc. demonstrated their capability to handle extensive rebuilds with precision and expertise, providing a seamless and effective solution for the client.

Key Highlights

• Project Complexity: Tackled extensive fire damage, requiring a complete rebuild of critical press components.
• Precision Machining: Ensured all rebuilt components met exact specifications for reliable and effective operation.
• Efficiency: Completed the project efficiently, minimizing downtime for the client and ensuring a quick return to full production capacity.
• Expertise: Extensive experience in handling complex rebuilds and restorations, providing comprehensive solutions to restore damaged equipment.

For more information or to discuss how All Enterprises Inc. can assist with your machinery rebuild and restoration needs, please contact us.

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An aluminum extrusion manufacturing facility initially tasked All Enterprises Inc. with rebuilding a damaged container housing and die shaft. During the three-week project, additional issues were discovered, requiring a comprehensive repair solution during a critical shutdown. 

Challenges

1. Initial Scope and Timeline: The original scope involved rebuilding a container housing and die shaft within a three-week period during a planned shutdown. 
2. Uncovered Issues: Upon disassembly, numerous additional issues with the press were discovered, including damaged side cylinders that were too loose, affecting the press's alignment and performance.

Innovative Solutions

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All Enterprises Inc. employed a strategic approach to address these challenges effectively:

1. Expanded Scope: The team at All Enterprises Inc. adapted to the expanded scope by identifying and addressing the myriad of additional issues discovered during disassembly. Identifying the issues, building a plan that proposed options on addressing the damage discovered and adjusting accordingly to incorporate the additional scope. 
2. Cylinder Removal and Repair: The damaged side cylinders were removed and repaired to ensure proper alignment and functionality of the press. The loose cylinders were a significant issue that required precise machining and adjustment, which was all completed with All Enterprises’ in-house machine shop. 
3. Shut Down Timeline: Many facilities have tight production schedules with very little flexibility for extended duration shutdowns, so we develop solutions that prioritize efficiency and minimize downtime, ensuring that repairs and installations are completed within the shortest possible timeframe.

Project Outcome

The project was completed successfully and addressed all of the additional scope, ensuring that the press was put together to last. All Enterprises Inc. demonstrated their capability to adapt to unexpected challenges and provide comprehensive repair solutions.

Key Highlights

• Project Complexity: Tackled an initial rebuild project that expanded in scope due to numerous uncovered issues, requiring adaptive and comprehensive solutions.
• Expertise: Extensive experience in handling complex machinery repairs and providing effective solutions for unexpected challenges.

For more information or to discuss how All Enterprises Inc. can assist with your machinery repair and maintenance needs, please contact us.

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A facility experienced recurring issues with their press, which broke tie rods every year under the maintenance of another contractor. All Enterprises Inc. was brought in during a Christmas shutdown to de-stress and properly repair the press.

Challenges

1. Recurring Tie Rod Failures: The press broke tie rods annually, indicating improper alignment technique and maintenance methods by previous contractors.
2. Inadequate Previous Repairs: The previous contractor used overtonnage on the press to tighten components, which was insufficient and led to repeated failures on an annual basis.

Innovative Solutions

All Enterprises Inc. employed a strategic approach to address these challenges effectively:

1. Comprehensive De-Stressing: The team completely de-stressed the press by removing all the nuts, cleaning every component, and ensuring proper alignment and function.
2. Calrod Utilization: The tie rods were drilled for calrod holes, which were used for heating and proper stress distribution. This method provided a more effective and lasting solution compared to the previous overtonnage approach.
3. Experience: Having extensive history working on presses with similar issues, we were able to explain to our client how the repeated approach of using overtonnage was the root cause of the issue for tie rods breaking, and offer an alternative approach that we know, through experience, has resolved similar issues in the past.

Project Outcome

The project was completed successfully during the Christmas shutdown, with the press going 15 years without breaking a tie rod after the repairs made by our team. All Enterprises Inc. demonstrated their capability to provide long-lasting and effective solutions for complex issues.

Key Highlights

• Project Complexity: Tackled recurring tie rod failures by employing innovative de-stressing and heating techniques.
• Precision and Efficiency: Utilized calrods and proper tooling to ensure the tie rods were correctly stressed and the press was effectively repaired.
• Long-Lasting Solution: The press operated without breaking a tie rod for 15 years after the repair, showcasing the durability and effectiveness of the solution.
• Expertise: Extensive experience in handling complex machinery repairs and providing innovative solutions for long-term reliability.

For more information or to discuss how All Enterprises Inc. can assist with your machinery repair and maintenance needs, please contact us.

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