Since 2008, our customers have created thousands of new jobs through improved paint finishing, opened new facilities, expanded existing ones, and brought billions in production back to the USA. Improved paint finishing operations have added many billions of value to their businesses. Many NAPaint projects have 1 or 2 month ROI. Annual benefit can exceed tens of millions.
FANUC ROBOGUIDE PAINTPRO SIMULATION
There are many tools available for the development of efficient automation. Fanuc's RoboGuide PaintPro simulation software is tailored specifically for Fanuc paint robots and accessories. Production programs, automation cells, and processes can both be developed, evaluated, and cycle tested offline, and even off site, so that operators and engineers can focus on running production.
Once a virtual paint robot cell is set-up to develop and drop programs directly into your factory robots, Fanuc's RoboGuide PaintPro can become an essential tool for any Fanuc programming developments or continuous improvements.
Skilled programmers can do the bulk of the paint robot pathwork and other robot related process controls without production downtime. This reduces the cost of the paint automation process development, eliminates risk of production and equipment damage, and speeds development. It also provides a neat way to illustrate the impact of efficient automation to operating costs. If you sense that your paint application process could be more efficient and productive, then the following video and analysis may interest you.
PROJECT: HARD TOP AND FREEDOM PANELS
A good sized midwest Tier 1 finisher of large automotive SMC hard tops and panels inquired about improving their Class "A" prime, base, clear paint process. During a 1-day site audit, NAPaint identified areas where improvements could be implemented.
Using only existing equipment, improvements were implemented that achieved the following gains in productivity:
Increased the rate at which good parts are produced by 125%. That's right, 2.25 sellable parts where now being produced in the same time 1 part took prior to improvements.
Decreased total paint used per part by 55%.
Eliminated 80% of paint overspray. Wowza!
Eliminated the need for most manual spray. This was extremely beneficial.
Eliminated 95% of robot and conveyor crashes.
Reduced total system downtime by more than half.
Achieved true Tier 1 Class "A" Paint quality in every category.
ROI less than 3 months and probably saved the business.
NAPaint later installed spray booth temperature and humidity controls.
All work was done during continuous production step-by-step and side-by-side with operation and maintenance, with only positive impact to the business. Instead of running 7 days a week, the plant was now running just 3. We had just created significant new capacity for extremely high margin new business.
Management pounced :)
Thanks for watching! Feel free to give me a call to discuss your process . . . Joe @ (708) 980-3758.
PROJECT: ROCKER PANELS
A Detroit area Tier 1 finisher of rocker panels acquired new business that required 2 component paint finishing. This upgrade (done by others) could not meet production needs, and in fact crippled production. Paint lines and equipment quickly became clogged with catalyzed paint, color changes were long and inefficient, critical automation of preset controls were rendered inoperable, and the solvent / waste recovery system plugged frequently. During a 1-day site audit, NAPaint identified the major system issues and cost-effective remediation.
Using only existing equipment, improvements were implemented that achieved the following gains in productivity:
Increased the rate at which good parts are produced by 263%. Yes, that's right, 3.63 sellable parts where now being produced in the same time 1 part took prior to improvements.
Decreased total paint used per part by 78.3%.
Eliminated 90% of paint overspray . . . not kidding.
Achieved full automation, no manual spray.
Implemented fast and efficient color change processes.
Configured waste / solvent recovery system for reliable operation.
Implemented cap clean cycles without line stoppage.
Reduced total system downtime by more than half.
Achieved true Tier 1 Class "A" Paint quality in every category.
ROI less than 3 months and probably saved the business.
All work was done during continuous production step-by-step and side-by-side with operation and maintenance, with only positive impact to the business. Instead of running 7 days a week, the plant was now running just 2 (once all the old rework was gone). We had just created significant new capacity for extremely high margin new business.
Management really pounced here :)
Thanks for watching! Feel free to give me a call to discuss your process . . . Joe @ (708) 980-3758.
PROJECT: REAR HATCH LIGHT PANELS
A Michigan manufacturer of light panels inquired about improving their paint process. During a 1-day site audit, NAPaint identified areas where improvements could be made.
Using only existing equipment, improvements were implemented that achieved the following gains in productivity:
Increased the rate at which good parts are produced by 49.5%.
Decreased total paint used per part by 40%.
Reduced scrap by 26%.
Eliminated 90% of paint overspray . . . seriously.
ROI of 1 month.
All work was done during continuous production step-by-step and side-by-side with operation and maintenance, with only positive impact to the business. Forty percent of the paint used in the original production paint process formed paint overspray, contaminating the spray booth, flash tunnels, and ovens. Spray painting was repositioned to the center of the booth where normal booth downdraft can efficiently remove it. Paint application process parameters did not change. Submission for production part approval (PPAP) was not necessary.
Thanks for watching! Feel free to give me a call to discuss your process . . . Joe @ (708) 980-3758.
