CASE STUDY
Eliminating Machining Process Variables
How Hogge Precision automated coolant management to eliminate concentration variability, reduce waste, and recover skilled machining time.
20-30 min
Time Saved per Machine/Day
18
Machines on System
~$40/gal
Coolant Overcharge Avoided
THE CHALLENGE
Hogge Precision machines a wide range of materials, from stainless and alloy steels to aluminum, brass, copper, bronze, castings, and plastics. Each material and machining process places different demands on tooling and metalworking fluid.
Hogge runs a water-soluble oil coolant, and the ideal concentration for most applications falls between 7 and 10%. Maintaining that concentration, however, had historically relied on operator vigilance, and operator attention is a finite resource.
"The concentration was terribly low, just over 4% when it should have been above 7%. That single oversight was destroying tooling on one of the more demanding materials we machine." - Danny Hogge, Owner, Hogge Precision
THE TURNING POINT
About two years ago, Hogge had been running 6061 aluminum on a turning center for several months. Aluminum is forgiving with respect to coolant concentration, and over time operators stopped monitoring it as closely as the process required.
When that job ended, the next job called for tapping a 3/4-16 thread approximately 1-1/2 inches deep in pre-hardened 17-4 stainless steel. The setup operator struggled immediately with cutting tool life and worked through the usual troubleshooting steps before a simple question was raised: had the coolant concentration been checked?
4%
Actual coolant concentration when the tooling problem surfaced
7-10%
Ideal Concentration Levels
15%+
Concentration after manually adding straight coolant to correct the problem
The operator resolved the tool-life issue by adding straight product directly to the sump, bringing the concentration well above 15%. The problem was solved, but the approach highlighted a second issue: manual correction could quickly turn an under-concentration problem into coolant waste.
The experience showed Hogge that the bigger opportunity was not simply to correct coolant concentration when problems occurred. It was to maintain the process consistently from the start.
THE SOLUTION
The incident sparked an initiative to remove routine coolant concentration management from the operator's daily workload. Hogge worked with its long-time coolant supplier, King Industrial of Lamar, SC, to pilot a system King was already prototyping for this purpose: the Coolant Commander.
The Coolant Commander uses a combination of sensors and measuring devices to maintain each machine's coolant level and concentration within the desired range. Its logic is straightforward: if concentration is within the acceptable range, it adds water only to maintain fill level. If concentration drops below the target, it introduces fresh product during filling and continues until the concentration returns to the ideal level.
Each machine now has its own Coolant Commander unit operating as part of a centrally managed system.
THE RESULTS
After six months of successful pilot testing, Hogge expanded the Coolant Commander system across all 18 machine tools in the facility. The impact has been consistent across the shop floor:
20–30 min saved per machine, per day
previously spent manually measuring concentration and refilling sumps.
6–9 hours of skilled labor recovered each day
across 18 machines, allowing machinists to spend more time on machining, troubleshooting, and process improvement.
More consistent tool life
across machining processes, reducing unplanned interruptions and helping improve production consistency.
Less coolant waste
by eliminating the need for manual overcorrection when concentration falls outside the desired range.
The benefits extend beyond coolant management. By taking a routine maintenance task out of the operator's daily workload, Hogge Precision has reduced one source of process variability while giving skilled machinists more time to focus on the work that directly affects production.
For Hogge's customers, that means a more controlled manufacturing process, fewer sources of unexpected downtime, and less lead-time risk. The goal isn't simply to automate coolant management. It's to create a more consistent process from one job to the next.
THE TAKEAWAY
This initiative reflects the way Hogge Precision approaches operational challenges: identify a root cause, partner with the right supplier, test rigorously, and implement systematically. Automating metalworking fluid management removed a chronic source of variability from the shop floor and replaced it with a reliable, measurable process.
For customers, that means more consistent production, reduced lead time risk, and a supplier actively investing in process control, not just responding to problems when they occur.
Ready to get started?
For more than 35 years, Hogge Precision has been a leading supplier of superior quality precision machined parts and assemblies for customers around the world. Our experienced team, working from our cutting-edge, AS 9100 D / ISO 9001:2015 registered facility, is dedicated to delivering top-quality products with a personal touch and a commitment to integrity. To learn more about our precision machining services, contact our team. We look forward to helping with your next project!
Or call us at: 843-332-3566