November 28, 2025

“Three Steps to Achieve Real Results with WELL AIR” — A Practical Guide to Installation & Performance Measurement

In the previous article, we shared how a machining manufacturer eliminated their “daily morning water-draining routine” and reduced equipment troubles by introducing WELL AIR.

As a continuation, this article explains:

How should you implement WELL AIR to ensure results?

What should you measure — and how — to clearly demonstrate its impact within your organization?

We break it down into simple, beginner-friendly steps.

 

 

 

■ STEP 1: Visualize the “hidden workload” in your current operations

 


The first step doesn’t require specialized measurement tools.

It’s simply about identifying what maintenance teams actually struggle with — using time and frequency as the two main indicators.


 

(1) Daily morning maintenance time

 

 

  • Checking end-of-line traps

  • Draining accumulated condensate

  • Startup condition checks

 


Example:

10 minutes/day × 20 working days → 200 minutes/month (3+ hours)


 

(2) Monthly trouble occurrences

 

 

  • Cylinder operation failure

  • Solenoid valve sticking

  • Insufficient air blow causing micro-stoppages

 


Even a small number of incidents can lead to large production losses, so recording each one matters.


 

(3) Filter replacement frequency

 

 

  • Filters per month/year

  • Man-hours for replacement

  • Inventory and planning load

 


These items often show the biggest improvement after installing WELL AIR.

 

 

 

■ STEP 2: Choose the optimal installation point

 


What’s most important next is where WELL AIR is installed.


 

Conclusion: The closer to the end of the line, the more effective.

 


Why?

Because long piping distances cause re-condensation — even if upstream dryers are functioning correctly.

 

 

 

■ Recommended installation points

 


 

◎ CNC lathes & machining centers

  • Chuck air

  • Workpiece suction

  • Internal spindle air seal

 


 

◎ Food & beverage lines

  • Pre-blow-off areas

  • Cap marking zones

  • Post-wash drying stages

 


 

◎ Plastic injection molding

  • Mold open/close air circuits

  • Pick-and-place suction

  • Workpiece air drying

 

 

◎ Steel industry (high humidity, long piping, heavy condensate)

Steel plants have extremely long piping, high humidity, heat sources, and dust — conditions that frequently cause re-condensation and contamination at pipe ends.

This makes them one of the best-fit industries for WELL AIR.

 

 

 

■ STEP 3: Measure the improvements after installation

 


After installation, focus on these four evaluation points:

 

 

 

① Daily morning maintenance time — Has it dropped to zero?

 


Check:

 

  • Amount of water in traps (photos help)

  • Whether draining operations are still needed

 


Most plants experience:

10 min/day → 0 min/day

 

 

 

② Trouble frequency

 

 

  • Before: 3 failures/month

  • After: 0–1 failures

 


Significant drops are especially seen in cylinders and solenoid valves.

 

 

 

③ Filter lifespan extension

 

 

  • Fewer replacements

  • Lower inventory cost

  • Noticeably reduced filter contamination

 


WELL AIR acts as a pre-filter, extending downstream filter life.

 

 

 

④ Reduction in equipment stoppages and micro-stops

 


Downtime caused by condensate contamination often disappears completely.


A single avoided micro-stop can save tens of thousands of yen —

meaning WELL AIR often pays for itself with just one prevented incident.

 

 

 

■ Example results for internal approval

Item

Before

After

Improvement

Morning water-draining

10 min/day

0 min

200 min/month saved

Cylinder failures

3/month

0

Reduced maintenance load

Filter replacements

2/month

1/month or fewer

50% reduction

Condensate-related stoppages

1–2/month

Almost 0

Increased uptime

 

Presenting results this way makes internal approval far easier.

 

 

 

■ Summary

 


The key to successful WELL AIR adoption is:


 

1. Quantify the current workload

 


 

2. Install at the optimal (end-of-line) position

 


 

3. Measure improvements in time, frequency, and cost

 


By following these three simple steps, WELL AIR becomes not just “something that seems useful,”

but a proven tool that demonstrably reduces cost and maintenance burden.

 

 

 

■ Next Article Preview

 


In the next article, we’ll discuss:


 

“How to maximize WELL AIR performance in oil-mist-heavy environments”

 


Including:

 

  • How it works in combination with oil mist separators

  • When to add membrane dryers

  • Optimization without additional maintenance load

 


Stay tuned.