Making robotic paint automation pay.  GUARANTEED!

 

North American Paint Applications

Specializing in Industrial Paint Process Optimization

 

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Products & Services

  - Paint Process Optimization

  - Paint System Audit

  - Paint System Specification

    a Paint Color Change Efficiency

    a Paint Shop Throughput

    a Paint Overspray Reduction

    a Paint Robot Integrator

    a Paint Defects Analysis

    a Paint System Troubleshooting

    a Painting System Automation

  - Paint Supply & Delivery Systems

    a Dead Head Paint Supply

    a Recirculating Paint Supply

    a Flexible Colors Paint Delivery

    a Piggable Paint Supply System

    a Self-Flushing Paint Systems

    a Oil Free Paint Supply

    a Paint Sheer Reduction

    a Spray Booth Waste Collection

  - RoboGuide PaintPro Simulation 

  - ABB RobotStudio for Paint

  - Paint Flow Control

  - 2 or 3K Paint Dispensing Systems

  

  

  

  

  

Since 2008, our customers have created over a thousand jobs in paint finishing, opened new facilities, expanded existing ones, and brought millions in production back to the USA.  Improved paint finishing operations have added greater than $650 million to their businesses.  The average NAPaint project ROI is less than 5 months.  Annual benefit can exceed tens of millions.

 

 

MAXIMIZING THROUGHPUT

 

Throughput refers to the quantity of parts processed by a paint system in a given time.  By consistently and reliably maximizing throughput, the cost per part decreases while the quantity of finished goods increases.  Such a combination allows businesses to be managed with more flexibility and profit.  Many aspects of a paint application system affect, limit, or control the level of throughput that is obtainable from a paintshop.

 

North American Paint Applications is the world leader in the implementation of methods for increasing throughput for every type of paint application.  When we say improve throughput, we mean it.  We look forward to spending a few days in your paintshop reviewing the possibilities with you. 

    

Part rack design that maximizes system performance and part window utilization coupled with efficient automation are critical for achieving maximum productivity and system performance.

High end SUV rear spoilers base / clear application. Quality finishing with high throughput and yields can often be significantly more profitable than lower throughput with higher transfer efficiencyLess than 4 seconds per spoiler!

    

PART DENSITY and RACK DESIGN

 

Poor part rack design can cut throughput in half, or more.  Poor part rack design can significantly increase the number of defects in the finished product, reducing yields by 50%.  Poor part rack design alone can reduce the overall productivity of your system by two-thirds.  

 

It is difficult to visualize how you might achieve 8 parts on a rack rather than 4 without a thorough understanding of the process and operational limitations of your system.  Robot reach and wrist orientation, applicator type and capability, flash times, and paint properties are some important considerations.  You don't know what you don't know, and it could be costing you big.

 

Rack design can also affect reliable part grounding, fire safety, and consistency.  

 

 

PAINT ROBOT PROCESS PROGRAMMING and INTEGRATION

 

There is much that can be done in the programming and set-up of the paint robot to increase throughput.  Once you have a suitable part carrier, a well designed robot program  will increase throughput, quality, and yields dramatically.  Our programmers implement continuous spray path throughout the job cycle maximizes painting time.  Triggering paint off the part or triggering when no part is present, improper head to target distances, improper angles of application, jerky motion, excessive mechanical force in abrupt turn around points, excessive atomization, and large spray patterns are a few of the control variables that profoundly affect the operational efficiency of automated systems.  Achieving automation only finishing can increase throughput, yields, and quality.

 

A robot fault, for any reason, can often severely impact both up-time and first time yields.  An efficient paint robot programmer will prevent robot faults associated with any movements, singularities, line stops, limits, or applicator operation .  Our programmers avoid over rotated and contorted wrist movements that damage applicator tubing and cables.  Turbine flooding, paint spits, excessive paint build-up, HV faults, color mismatch, lights and heavies, poor color changes, and crashes are all preventable with efficient programming and integration.

 

When two or more robots paint the same target, with perhaps door openers incorporated, a well conceived and orchestrated application program can have a dramatic impact on throughput.

  

 

PAINT SUPPLY

 

An adequate and reliable paint supply is essential to maximizing throughput.  A paint shop may utilize a conveyor with the most accurate speed control; it may have installed extremely reliable robot mounted applicators; but if paint cannot be accurately dispensed, then the high performance of the conveyor and robot applicators, dearly bought, may equate to money spent without return.  Inconsistent paint supply can contribute to increased requirements for manual spray.

 

Stopping conveyors or idling equipment to change colors, cans, drums, or totes can have a tremendous impact on equipment utilization and throughput.  

 

 

APPLICATORS

 

Many types and sizes of applicators are available for applying your material including rotary atomizers, conventional air spray, high volume low pressure (HVLP), air assisted and airless, both in electrostatic and non-electrostatic types.  Utilizing the right applicator for your process ensures that production and quality levels can be met.

 

 

EQUIPMENT LIMITATIONS

 

The proper specification and application of equipment is essential to obtain maximum throughput.  Often, exchanging one or two restrictive components with properly specified replacements can have a tremendous impact on throughput.  NAPA can provide an experts perspective to identify all such opportunities in your paint shop.

 

 

CONVEYOR SPEED and UTILIZATION

 

The speed of the conveyor can be limited by any phase of the paint application process including load, pre-treatment, paint application, curing, unload, or for quality reasons.  It most facilities, conveyor speed ought to be limited by the existing curing and oven infrastructure.  If it is limited for any other reason, North American Paint Applications can probably help you speed it up to increase throughput.

 

Power and free conveyors are often poorly synchronized with automation, causing avoidable delays in every job space.

 

Conveyor utilization refers to the percent of the conveyor, in a given time, that produces product.  This includes conveyor stoppage.  Product gaps on the conveyor are often purposely left for changing colors and for other reasons.  Robots can sit idle as a result.  Manual sprayers can stop the line.  Sometimes, entire conveyors are stripped of product at the end of each day.  Often, regular manual tasks require the conveyor to be stopped.  Whatever the reason, any time the conveyor is empty or stopped, nothing is produced.

 

North American Paint Applications can provide a thorough analysis of your entire process to outline methods for improving conveyor utilization.

 

  

PRE-TREATMENT

 

Most parts require some sort of processing prior to painting.  Cleaning, phosphating, rinsing, electo-coating, drying, wiping, dusting, blowing, ADPro, and flaming are a few common pre-treatments.  These systems ought to be designed to perform efficiently, repeatably, and with sufficient flexibility.  Problems such as inadequate cleaning, poor phosphating, spotty electro-coating, or water marks should never occur when suitable equipment is functioning as designed.  Dirt on parts is possibly an indication of contamination from pre-treatment systems.  

 

  

CURE

 

The existing curing and oven infrastructure, and controls, are often the determining factor for limiting throughput through the paint process.  NAPaint can analyze your curing process and quickly determine whether or not it is achieving the highest levels of throughput. 

 

  

QUALITY

 

Maintaining high quality standards of the finished product can significantly affect throughput.  For example, a speed up in conveyor may result in uneven film distribution across the part.  Reducing gaps in the conveyor may result in overspray contamination.  An increase in flow rate from the applicator may result in solvent pop or blistering during curing.  Paint processes have an endless list of cause and affect that must be carefully considered when maximizing throughput and line yields.

 

 

 

 

    

 


 

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North American Paint Application Co.

info@napaint.com

www.napaint.com

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