Manufacturing facilities in today’s competitive market strive to produce the highest quality product. In this case study we will discuss the importance of recognizing every company’s desire to produce a premier product with the highest first place transfer efficiency.
A Custom Fabricator, producing products for the truck & and Bus industry
In order to distinguish them within the marketplace, the current manufacturing process needed to meet customer’s mil specs. Their current Powder Units were not producing enough Mils per MFG spec with a Quality finish. Examination by quality control engineers revealed that they were getting back ionization and orange peel when applying more powder and second coats. They determined that each operator had different settings and too much powder output. In addition they did not understand current and voltage and how they relate to a quality finish and high transfer efficiency.
In partnership with the customer, Air Power implemented an Gema OptiFlex 2 manual powder unit. The unit comes with 3 presets: 1: Flat Parts, 2: Recess/complex parts and 3: Recoat mode. In addition these cannot be changed by the operator and allowed ease of use with a simple repeatable process. The Patented Digital Valve control allowed for consistent precise powder output, powder savings, and reproducible coating results.
Currently, the customer is meeting their mil spec and producing repeatable results and has increased there transfer efficiently that has provided a 1 year Return on equipment investment.