Lean Series Part III: Determining the Amount of Motion Waste in Paint Production Process

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Motion waste refers to the extra physical steps taken by employees and equipment to accommodate inefficient process layout, defects, reprocessing, overproduction or excess inventory. Additional and unnecessary motion takes time and adds no value to the product or service.

Moving and adding value is called work. Moving and not adding value is adding costs to your company and is motion waste.

IntelliFinishing removes motion waste simply by its technology and design. We know we cost more than an average Power and Free system. We are okay with that, because we know the value our completely automated finishing system adds to our customer’s production processes and profit margins.

Here is how we add value and help our customers remove motion waste:

  • SMALL FOOTPRINT
    Many of IntelliFinishing’s system layouts result in a smaller footprint than systems that use overhead monorail conveyors or power and free conveyors. A smaller footprint ultimately means less conveyor to maintain, less floor space operators have to cover and a reduction in the space requirements of your building. An Intellifinishing system can be designed within a smaller footprint because:

    • the conveyor does not have a chain so you don’t have to plan for the return chain
    • our conveyor moves forward and backward allowing you to spur parts to a masking area or load/unload area
    • we use shuttles or deadheads for large parts eliminating the need for large bulb turns
    • we give you flexibility within zones, allowing the conveyor to run faster or slower based on the process, eliminating the need for a large oven
  • LAYOUT DESIGN FLEXIBILITY
    When we are designing systems, we look for ways to share operators and resources between stations. In one system, we were able to position the mask and unmask stations next to each other, allowing for one person to perform both tasks. Frequently, the same resources may be used for loading and unloading since the system can stop in a zone without affecting other areas.
  • SYSTEM OVERVIEW DISPLAY AT ALL HMIs
    Operating stations track each carrier within each zone allowing you to quickly identify any issues and exactly where it is located, saving time and money in motion waste. Work instructions may also be displayed at stations and are useful for masking and labeling instructions.
  • SPEED UP THROUGH NON-VALUE ADDED ZONES
    IntelliFinishing complete paint systems give you the ability to move at variable speeds within zones, along with the value added option to stop the line within a zone or process without affecting the rest of the line, eliminating unnecessary movement of equipment.
  • DECREASED MOVEMENT EQUALS FEWER INJURIES
    With less overall movement by workers and equipment, the chance of injury decreases. Have you ever wondered how beneficial decreased movement can be to your bottom-line? For example, the average back injury (sprain/strain) can cost more than $10,000 in direct costs (National Safety Council Statistics) and anywhere from $30,000 up to $100,000 in indirect cost. The direct cost for all U.S. workers out of work due to Musculoskeletal Disorders or MSDs is estimated at $13-20 billion annually with indirect costs between $26-110 billion annually.

Complete Paint System Open House – Albers Finishing & Solutions

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Interested in learning more about IntelliFinishing’s powder coating or liquid paint systems? Join us on March 24, 2016 and see our newest installation in full production mode at Albers Finishing & Solutions in Cheney, KS. Our IntelliFinishing team will be available all to day to answer questions and highlight all of the features we offer in our complete finishing systems.

Albers open house

Albers Finishing & Solutions, located in Cheney, Kansas, would like to announce they will host an open house at their facility located at
38628 West 15th St. South
Cheney Kansas 
10am to 3pm on March 24, 2016
RSVP

Cheney is located 30 miles west of Wichita on Highway 400.

Review a simulation and to sign up, visit www.intellifinishing.com/albers.

Albers Finishing & Solutions provides liquid paint services to regional and national customers. The highly automated paint line has a part window of 2’W x 4’H x 8’L and can handle up to 500lbs of weight on each load bar.  Albers Finishing & Solutions was created in response to a local manufacturer who had a need to provide a finished product but didn’t want to stray from their core business by adding paint inside their operation. Albers Finishing & Solutions took on the challenge of solving the client’s needs while at the same time building a versatile facility that can serve many industries.
Currently, the liquid paint line is capable of painting 2,000 to 3,000 parts per day and features an automated conveyor that moves load bars forward and reverse or even stops them independently of every other load bar in the system, a three-stage wash, dry off oven, two paint booths equipped with Fanuc robots applying liquid primer and paint via automated paint mix equipment, a dual-lane energy-efficient cure oven and a load-assist lifter.

The line was designed and installed by IntelliFinishing based out of Salina, KS. Woody Miller, IntelliFinishing’s project manager states, “This paint system offers some of the best and newest advances in the industry. With advanced automation and controls, energy efficiencies, and floor space savings, the cost to paint each part is less than other systems. This is a very high-end system, located here in Cheney. Other manufacturers are struggling with their “monument” systems and would love to have a system like this.”

IntelliFinishing teamed up with Downey Consulting, a local company in designing the following for the system: load-assist lifter, carriers, loadbars, hangars and a rotator mechanism in each paint booth. The parts are hung on a custom loadbar with a spinner wheel, and spun utilizing the air operated (intrinsically safe) rotator.  All of this is controlled by the PLC.  The wireless lifter mechanism is capable of removing the loadbar from the carrier fully loaded with parts, placing finished product on racks, or changing loadbars for a different type/style of part.  This allows the ultimate in flexibility of the system.

Bret Albers of Albers Finishing & Solutions states, “Albers Finishing & Solutions will be launching with some of the latest technology available in the paint industry.  The IntelliFinishing system provides the ultimate in flexibility, automation and energy saving features.  Being fully automated and robotic allows us to provide clients with a consistent product each and every time. On top of that IntelliFinishing has the best support team in the business.  Their design team, installation crew, programming staff and marketing are second to none.”

“In addition to superior quality and consistency, companies choosing Albers Finishing & Solutions will also experience the ultimate in customer service.  Our goal is to be your partner, not just another contractor.  We understand how important turnaround times, communication on the status of your product, quality control, and proper packing are to the success of your business so come by and check us out to see what we can do for you,” explains Bret Albers.

Plans to expand the business include powder coating and anodizing processes.

The owners of Albers Finishing & Solutions have been involved in other businesses including: Art’s & Mary’s Tater Chips, Leadfoot Express Transport and D’Mario’s Pizza Outlets.

 

Choosing a Conveyor

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Conveyors for Finishing Systems

The selection of a conveyor for your powder coating system or liquid paint system at your manufacturing plant should be based on the features and benefits of each of the conveyors, part and process requirements, as well as your business goals.

There are three types of automated overhead conveyors typically used in finishing systems:

  • Monorail conveyors
  • Power and Free conveyors
  • IntelliFinishing conveyors

The layout should be configured to move parts from the loading point in the fabrication area through the finishing system to the unloading point in the assembly or shipping area. The goal is to minimize wasted movement, damage to the parts and personnel while providing the desired finished quality.

Monorail Conveyor Description

Overhead Monorail Conveyor
A monorail conveyor is simple and efficient but lacks flexibility.

Overhead monorail conveyors have the load-carrying and the drive functions combined in one element—the endless chain. The chain is guided by a rail system based on either an I-beam or an enclosed track. A take-up unit ensures that the chain is pulled tight as it leaves the drive unit. A caterpillar drive or sprocket drives the chain. Parts are suspended from the chain by special attachments or load bars. This conveyor can follow only one path. No other paths or spurs for masking, maintenance, labeling, loading or unloading are typically part of a monorail conveyor system.

Advantages: simple, efficient, low initial cost, best used for a single type of part and process

Disadvantages: no layout flexibility for part variety or process changes, any line stop or breakdown stops entire conveyor, no ability to stop for a process (masking, touch-up, labeling) without stopping entire conveyor, chain maintenance, take-up unit adjustment and monitoring, lubrication can cause issues with the quality of the parts, noisy

Video:
Monorail Conveyor

Power and Free Conveyor Description

Picture of power and free
Power & Free conveyors use a two-rail system and pusher dogs to allow for more flexibility than a monorail system.

Overhead power and free conveyors are two-rail systems. The trolley is the load-carrying element and is located below the chain. The trolleys use the lower “free rail” and the chains are in the upper “power rail.” Pusher dogs establish the connection between chain and trolley and can be engaged (dogging and de-dogging) and disengaged as needed. The “free rail” can be equipped with switches, lifting stations or stops to allow the trolleys to follow different paths, or be lifted or lowered, stopped or moved at different speeds throughout the system. The entire conveyor system is PLC-controlled.

Advantages: flexible layouts for variety of parts and processes, stop and start, multiple speeds, reduction in personnel since parts may be stopped, trolleys can be buffered, part tracking, integration to ERP, process recipes

Disadvantages: higher initial cost than monorail conveyor, any line stops or breakdowns stop entire conveyor, more layout options require more chain, return chain, speed changes require multiple chains and drive motors, chain maintenance, take-up unit adjustment and monitoring, lubrication can cause quality problems, part swing since there is no accelerate or decelerate, no ability to reverse direction reduces layout options, no ability to reverse when there are problems requires complete chain to be stopped, noisy

Videos:
Dog Magic Chain Conveyor (Daifuku North America)
Power & Free Conveyors (Daifuku Webb)

IntelliFinishing Conveyor Description

IntelliFInishing Spinning Tube Friction Drive Conveyor
An IntelliFinishing conveyor system provides ultimate flexibility using a spinning tube friction drive requiring no chain.

The IntelliFinishing conveyor provides even greater flexibility than power and free because the movement of the trolley is performed with a spinning tube by a small motor. Each section or zone of an IntelliFinishing conveyor may be independently controlled with a variable frequency drive (VFD) and the entire system is PLC-controlled. Data handling and smart controls with recipes for a variety of parts provide even greater flexibility and automation. With “no chain”, driving the system, many of the issues like maintenance, noise, chain jams, take-up problems, lubrication ruining finished parts, de-dogging, floor space for return chain, etc. are not an issue for an IntelliFinishing automated finishing system. The trolley (propelled by the spinning tube) moves forward and reverse which provides more layout options and decreases production stoppage and downtime when compared to power and free conveyor system.

Advantages: flexible layouts for a variety of parts and processes, stop and start, multiple speeds, can stop individual motor sections independent of each other allowing remainder of conveyor system to run, reduction in personnel since parts may be stopped, trolleys can be buffered, part tracking, integration to ERP, process recipes, accelerate, decelerate, reverse, minimal maintenance and no chain lubrication, reduction in floor space, lower energy and resources since processes run only when a part is present, expandable, modular and moveable, more adaptable for lean manufacturing

Disadvantages: higher initial cost than monorail conveyor, more options may cause increase in costs because of drives and motors, limitations on inclines and declines, larger elevation changes require lift sections

Videos:
IntelliFinishing System Overview
IntelliFinishing Shuttle for Large Parts
IntelliFinishing Paint System at Raytheon

 Advantages of Overhead Conveyors

Monorail

  • simple
  • efficient
  • low initial cost
  • best for single part/process
Power & Free

  • flexible layouts
  • stop & start
  • multiple speeds
  • buffering
  • part tracking
  • integration to ERP
  • process recipes
IntelliFinishing

  • flexible layouts
  • stop & start
  • multiple speeds
  • buffering
  • stop sections without stopping whole line
  • part tracking
  • integration to ERP
  • process recipes
  • accelerate
  • decelerate
  • reverse
  • minimal maintenance
  • no lubrication
  • reduction in floor space
  • expandable
  • modular
  • moveable

Disadvantages of Overhead Conveyors

Monorail

  • no layout flexibility
  • chain maintenance
  • take-up adjustment
  • lubrication
  • noisy
Power & Free

  • higher initial cost (vs. monorail)
  • chain maintenance
  • take-up adjustment
  • lubrication
  • noisy
  • more layout options require more chain
  • return chain
  • part swing
IntelliFinishing

  • higher initial cost (vs. monorail)
  • limitation on incline & decline

12 Days of Christmas IntelliFinishing Style

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View the 12 Days of Christmas IntelliFinishing Style VideoThere’s not a better time of year to think about a new complete finishing system. Peek through the pages of the 12 Days of Christmas IntelliFinishing style to see all the benefits and advantages of choosing our alternative to power and free system.

From the first day of Christmas to the 12th, we have something special for you.  View the video at http://intellifinishing.com/12days.html