Can You Color Change Too Fast?

Manufacturing facilities strive to improve the quality of their finish while reducing color changeover time in an effort to produce the most desirable product quickly. In this study we will discuss the importance of recognizing every company’s desire to improve in these areas and how improvements can be made within a custom powder coating operation.

Customer

 

A local wheel remanufacturer and custom coater located within North Carolina.

Challenge

 

This facility was constantly losing valuable production time due to quality rejections.  Once rejected, the part was reworked and coated a second time.  This caused a cumulative effect on both powder usage and man hours proving rework within this facility a high cost and overhead factor.  In addition, the existing manner of color change resulted in the facilities inability to keep up with current workload. Daily operation consisted of: 4 main colors, an occasional “custom” color, and a clear coat.

Air Power’s Solution

 

Air Power proposed a Gema OptiFlex 2 Wall Unit with multiple dedicated fluidizing hoppers.  These fluidizing hoppers are plumbed for the 4 main colors.  A Gema cup gun was provided for the “custom” colors and clear coat. Air Power was able to provide an onsite demo at the customers facility allowing the customer to test, prove, and inspect the proposed solution prior to investment.  The improvement in both quality product output and line throughput was dramatic.  In addition, the facility was impressed with Gema’s five (5) year manufacturer’s warranty and Air Powers local support and service.

 

Result

 

The immediate improvement was first observed within the finish quality which was noticed within the existing customer base.  Due to this improvement, repeat business was observed more readily and additional customers were earned, growing an ever increasing need for a more expansive customer base. Even though workload was increased, production never had to slow down. The quick color change system, with dedicated pump/hose combination, allowed operation to change color quickly removing the former bottleneck.   An added benefit of the system was the removal of pre-heating parts to achieve powder thickness and build.  This result was observed due to Gema’s industry leading transfer efficiency, new found operator control, and recipe programing within the system.

Can you color change too fast?  If you ask this custom coater the answer is no; and their ability to change colors faster with an increase in finish quality has taken the operation to new heights.

 

OptiFlex 2 Wall Unit color change system

 

Gema Gun with Cup for small and test batches

 

Tire Lifting Solution Case Study

Material Handling Need

Aircraft Tire/Wheel shop activities require significant handling of large aircraft tires and rims weighing up to several hundred pounds.  Handling these assets by manual means/methods had resulted in several serious injuries, culminating in lost work days and long-term medical impact on shop personnel and worker well-being.

Original Process:  Two to Three operators required to lift C5 aircraft tire from pallet position, stacked up to four(4) levels high and onto rim assembly.  Assembly was then lifted from horizontal position to vertical in order to be rolled into rack staging area.

Tire Lift weight: 400 pounds+

Tire Size:  44”-56” outside diameter(OD), 17”-20” width

Air Power Solution

Upon review of operations, AirPower solution consisting of aluminum overhead rail, bridge crane to suspend one (1) manipulator for the tire lift process, and one (1) bridge to suspend a pneumatic hoist for the F15 Rim process for the original C5 aircraft application. C5 Solution installed in 2013.

Due to increase in the C130 aircraft process requirements, Air Power was contacted to provide an additional solution for the C130 unit in September 2015.

An additional bridge was added, to allow processing for the larger C130 tire application (tires in excess of 400lbs) to allow pickup, positioning and processing of these components.

Air Power Inc provided a TurnKey solution for both C5, and C130 tire applications.

 

Results

Implementation will reduce injuries, enhance efficiency, improve quality and ergonomics in the support of the war fighter mission.

“An effective and user-friendly solution that was way overdue” –Bobby Munda, WRAFB 402MXE

“Awesome, absolutely awesome!” –Candace Lauderdale, Safety Specialists, WRAFB

Original Pick Up Method Pick Up Solution Original Set Down Method Tire Set Down Solution

QX Drives Quality

Challenge

In order to distinguish themselves within the marketplace the current method of assembly: non shut-off impacts, clutch tools, and hand wrenches, was not satisfactory. Examination by Quality Control Engineers revealed that some critical fasteners were working themselves loose during shipment and installation. Implementing an accurate solution to provide operator feedback and data collection was deemed necessary.

Air Power Solution

In partnership with the customer, Air Power implemented an Ingersoll Rand QX Precision Fastening System. This hand held, battery operated, solution provided a much more accurate final torque, while providing the operators with tightening status feedback, actual torque values, and 1,200 rundowns of tightening data for manual upload and review.

 

Goodbye to Manual Mixing

Introduction

Manufactures underground boring equipment for gas and water lines. Used “hot potting” or manually mixed 2 paint components to be able to spray two colors: yellow and black.

Background

This company has one booth for top coating and would manually mix the black and yellow paints. It took well over an hour to change out the colors. Parts being fabricated were staged all over the plant waiting to be painted. Due to backlog and space contingencies, some items were forced to be stored outside. Rainy days would slow down the process even more.

Air Power Solution

Air Power, Inc. suggested using a Graco Promix 2KE with gun flush box and utilize drum pumps they already had. Mixing on demand out of a 55 gallon drum of each component, improved the ability to change colors in less time than it takes to bring a new part to be coated.

Low Headroom-Low Pickup Solution

Customer Need

Customer installed new winders in a low headroom area which presented final product at a low pickup position. Rolls weighing 100lbs were required to be lifted from horizontal position, and placed into vertical stacked position onto pallet. Existing process required manual handling.

Area of equipment installation presented a restricted, low headroom area requiring the need to reach under, and around additional OEM equipment required for the winding process.

Air Power Solution

Upon evaluation of process, and area requirements, a dual extruded aluminum runway, with low profile carriage and custom adjustable stops were specified, and installed to provide coverage for the pickup and placement of rolls across a bank of six(6) winding machines. A custom steel frame was fabricated and installed in order to properly mount/position both runways for roll handler, and aspirator lines for the winding equipment. Due to area restrictions, an articulating arm with integrated air balancer was mounted to allow for reach under, and around process equipment, to allow for pickup and placement of the finished product.
A Dotec RH90Z45 Roll Handler (for low pickup) was provided which allows ergonomic pickup/placement of rolls to eliminate bending and manual handling by the operators of the finished product.

Roll Handling Solution for Flexible Packaging

Customer Need

An Arkansas based, Flexible packaging converters palletizing process required manual lifting and tilting of rolls being presented in the horizontal core position, onto a pallet- stacking to vertical orientation. The rolls being processed have weights up to 200 pounds, with roll widths up to 40 inches.

An existing overhead steel track was to remain in the process zone, which had to be considered for the process area location due to heights/clearance obstruction.

Air Power Solution

Upon initial discussion with manufacturer, end user contacted Air Power Inc, the Southeastern US Full service provider of Dotec Roll Handling Solutions, to discuss the project needs.Sample rolls were provided by the end user for evaluation.

A video demonstration by Air Power personnel was provided to end user, of the equipment proposed and in process.

A TurnKey solution was purchased, which included: One(1) Dotec RH90 Roll Handler – with auto roll engagement, ergo-handle controls, powered tilt function , One(1) Dotec 700LH Low headroom jib (to allow for coverage and clearance under the existing structure), Installation and Start Up training.

Results

Plant Manager Rod A. noted: “this is a welcomed tool for our operations, we have already identified additional areas which can benefit from this solution. Thanks to all for a job well done!”

 

Ingersoll Rand Advanced Tightening System

Air Power, Inc. presents a demonstrations of Ingersoll Rand’s Advanced Tightening System by Kyle Crawford