In the world of planning, there’s always the chance that something goes awry. These best-laid plans hit snags much of the time because of unforeseen challenges, especially during a pandemic. IntelliFinishing recognizes building automated finishing systems is a complex process—one with lots of specifications, including process equipment, paint application, conveyors, controls, the footprint, utility requirements and more.

While these projects have lots of moving pieces, we do everything within our power to meet our client’s expected operational date for beneficial use. We want every organization considering an IntelliFinishing system to understand our processes and commitment to their desired completion date as well as the most common reasons for delays.

Experience Matters

We have a wealth of experience on our side in installing automated finishing systems big and small. One of our largest systems contains a mile of conveyorized track and our smallest – just a few hundred feet! No matter the size of the job, our customers receive the same care when it comes to timelines. At IntelliFinishing, the priority to Meet Deadlines is only secondary to Safety and Quality in our stated and adhered to company values.

We’re proud to say that we’ve never had a customer unhappy with our efforts to complete a project within the agreed-upon timeframe. However, that doesn’t mean that all the planning and work don’t encounter unexpected delays. Below are some real examples, however we have not cited actual projects names or involved vendors…because we love our customers and suppliers!

What Are the Biggest Causes of Delays?

Our team tracks what causes delays or problems on every project so that we can be better prepared for the next job. 2020 has, of course, been a complete curveball! The strain of the pandemic on supply chains, safe workspaces, losing workers for a time due to infection and more have certainly had an impact. Beyond the challenges of COVID-19, here are the most common causes of delay for projects we’ve installed.

Weather

It’s unpredictable and outside of anyone’s control. Weather doesn’t usually slow down the building of a system, rather it often affects the building site.

On a recent project installed near Atlanta, the area received substantial rainstorms for weeks, creating a massive mud pit in the area that was the build spot. Since this was a new addition to an existing building, a slab was necessary to support the walls. The rain delayed the building contractor for weeks, preventing the delivery of the system equipment. In this case, the customer had been outsourcing their finishing needs prior to deciding to install an IntelliFinishing system, and we were able to complete the installation once the addition was available in a relatively short timeframe.

Another unexpected weather-related example includes an installation in an existing building where the customer experienced a roof leak around the ventilation of and above their liquid booths. This leak was causing problems with operating the system at regular capacity and meant the system could not be officially approved as per the project contract. We could not properly repair the roof ventilation until the rain stopped. However, the customer was effectively using the system, working around the leak problem, but we didn’t receive final approval on the project until the repair was completed – a few weeks after “the unexpected monsoon season”.

Equipment Purchases from Vendors Not on the Main System Contract

Companies often purchase items related to the finishing system apart from the main system contract. Examples include shot blasts, booths, application equipment, robotics, etc.

In a recent installation, we learned about two months into an eight-month project that vendors supplying an inline shot blast as well as those supplying system robotics, would be unable to meet their delivery deadlines and thus it delayed our installation schedule. To be absolutely fair, this situation arose, in no small part, because the procurement and negotiation process between the client and these vendors went longer than expected – thus delaying their delivery turntime schedules. Further exasperating these same delays were COVID-related supply chain slowdowns from overseas and other areas.

With these extenuating circumstances, our customer graciously removed the liquid damages clause that were a part of our contract with them. Meanwhile, we were able to meet our equipment arrival timelines and find workarounds for the delays of the other vendors. The system was up and running only a month or two later than originally expected. Ultimately, the client is extremely happy with the installation process and with their system.

Local Licenses and Utilities 

Ensuring a site has the appropriate licenses and utilities is integral to the installation. These aspects of an installation are usually the responsibility of the client, but since we act as general contractor for the system, we are often very involved in helping clients with these outside agencies. However, a few years ago, we worked with a client serving as their own general contractor. Unfortunately, they made an error in ordering the appropriate capacity of the natural gas line. It simply wouldn’t meet the requirements of the system equipment, resulting in a several-month delay. Fortunately, the system was able to operate its multiple cure ovens at half capacity after installation and ultimately, they obtained the proper sized gas line to feed all of their ovens.

Another project also related to delays due to utilities: In this case, the whole project was delayed due to the electrical company not installing their switchgear equipment when requested. As was their responsibility, the client requested a specific date for installation and many other tasks in the project were contingent on hitting that date. Utility companies, however, don’t always meet their requested install dates – and in this case it caused a cascade of task rescheduling.

Building Site Construction Delays

Construction, whether a new build or a remodel, is infamous for missing deadlines. A million things can go wrong with materials, labor, inspections, equipment and more. While we all know that construction timelines rarely meet expectations, the delays impact the system project, nonetheless.

Really Unexpected Situations 

The last category is everything else that you would never expect, but it’s happened. For example, we had a client who suffer a cybersecurity attack on their ERP system! Without their operating system, they couldn’t even carry out routine functions. They couldn’t even email us or send us their purchase order for several weeks! This actually happened over their holiday shutdown and for a week or two after it, so it wasn’t presumably during their busiest time of year, but it sure was frustrating for them while it was happening. Once they were able to restore their systems, we received the long-expected purchase order in plenty of time to start their project’s march to completion.

Things Rarely Go as Planned, but IntelliFinishing Adapts

There are so many possibilities of plans going askew that are outside of our control. We’ve come to learn that delays happen, so we adapt to ensure we do everything in our power to meet customer timeline needs.

At IntelliFinishing, we want to do more than just meet deadlines; we want to exceed customer expectations every time. The response from customers on our installation processes is overwhelmingly positive! As Bill Dunn, CEO of Manufacturing Resources International, said, “Everything was very efficient, and they were great to work with. It was amazingly smooth and painless.”

See How Our Systems Work

Our automatic finishing systems for liquid and powder coating are remarkably different. With a unique friction-tube conveyor and smart controls, it’s more efficient and process flexible than traditional chain-based systems and may take up a significantly smaller footprint, too. See how it works by watching some of our videos.

Variable frequency drives, or VFDs, provide efficient use of power, allow for productivity and control under different types of torque loads, and more.

After some brief information regarding motor controllers and torque loads, let’s explore the ABCs of these beneficial solutions – the applications, benefits and cost savings.

Different Types of Motor Controllers and Torque Loads

The core types of motor controllers are across-the-line motor starters, which come in full voltage non-reversing and full voltage reversing, soft start/stop controllers, and VFDs.

Across the line, full voltage starters send full voltage, typically 480VAC, to the motor – usually with an accompanying “clunk” that can even dim the lights. Essentially, these motor starters go “full throttle” as soon as they’re turned on.

That issue is slightly alleviated by soft start/stop motor controllers, which use a solid-state electronic device to ramp up the speed of the motor from 0 to 100% over a predetermined amount of time. It works the same way as it stops. This results in less wear and tear on the motor, but these still always go to full speed.

Finally, there are VFDs. Mountable in a motor control center or standalone, VFDs allow for the adjustment of motor speed over time, providing finer control while still realizing the benefits of less wear and tear on the motor.

There are also two central types of torque load. Constant torque loads exhibit roughly the same requirements, regardless of operating speed, while variable torque loads exhibit torque requirements that rapidly increase alongside machine speed.

In constant torque load applications, energy use is roughly proportional to speed. In variable torque load applications, energy savings aren’t linear.

Applications, Such as Finishing Systems, Benefits, and Cost Savings

In comparing soft-start/stop controllers to VFDs, SS controllers are primarily used for energy savings and to prevent excess wear and tear on equipment.

However, in applications such as an IntelliFinishing system, VFDs provide those same benefits while also offering the ability to adjust speed as necessary and to smoothly accelerate and decelerate carriers of parts as they travel through various sections of a system.

Ultimately, using a VFD on each motor controlling a section of friction tube conveyor on an IntelliFinishing system allows users to increase part density per carrier. This means more throughput in less time. This could amount to as much as 20% more throughput! Combined with the fact that most IntelliFinishing systems are monoplane in design, there are simply far fewer chances parts will bump each other as they wander through pressure washes, shot blasts, ovens, and booths for the typical finishing system set of processes.

Of course, it’s possible to use VFDs on indexing monorail systems or power & free chain systems too and this would greatly help with the amount of part sway often seen on these systems. That said, when a carrier of parts de-dogs or dogs from power & free conveyors, the inertial forces may still cause parts to collide if sufficient spacing between parts isn’t considered.

For an IntelliFinishing system, carriers can move at varying speeds per section, come to complete stops, and even reverse direction if desired (perhaps for a deadhead turn or to back up into a spur that may be a touch-up booth or for systems designed with shuttles that allow parts to enter a process and then back up out of that process when done.)

There are many other cases in which a VFD can provide measurable benefits to finishing systems and process equipment, such as on shotblast and wash motors.

Though installation costs are higher and there are other special considerations, such as more training for techs performing maintenance and special considerations to take into account, the added flexibility and easing of wear and tear on motors, plus the increased throughput can alleviate those costs over the life of the system and provide significant ROI.

IntelliFinishing is here to help you determine if our VFD-controlled, friction tube conveyorized automated finishing system might be the best fit for your unique needs and application. To learn more, contact us today.hh

Adding an automated finishing system to your operation can have a tremendous impact on efficiency, productivity and quality – and that’s why you’ve made the choice to invest in an industrial finishing system that matches your unique needs.

It’s also critical to get it right the first time and ensure the process results in a finishing system that not only delivers on its potential, but is ready to scale alongside your organization.

However, all customized automated finishing systems are expensive, likely costing your organization anywhere from $1 million to many millions in capital investment. While this investment will result in significant ROI and a lower lifetime cost of ownership, it’s still important to go see systems at work, especially if you don’t currently have an automated finishing system, before you even fully define your specifications.

So, when should you start your tour of systems currently in place and delivering benefits in real-world operations? The answer is as soon as possible.

Key Considerations to Help You Evaluate Systems You Visit

While seeing any system may help you understand how one might best fit into your organization, try to see one that:

• Seems to process parts that are similar to yours
• Uses processes that you’d likely want in your own system
• Has throughput levels about the same as you may need to hit your goals

But, even more importantly, don’t get locked into the traditional paradigm of an overhead, chain-based monorail or power-and-free conveyor.

Make a conscious effort to see something newer, more flexible and more modular, which can give you a better idea of the possibilities innovations have brought to life in automated finishing systems.

The IntelliFinishing Difference – See It for Yourself

IntelliFinishing automated finishing systems are unique and offer advantages that can’t be matched by traditional chain systems.

They provide recipe control per carrier, empowering you to finish a much wider variety of parts on the same system and let the recipe dictate the optimal process for each carrier of parts processed.

This allows you to cater to parts that require longer cure or paint times than others. Have extra-long parts that need to be finished in a relatively small space? A shuttle system can help to avoid large radius turns. Do you feel like your processes could change over time? IntelliFinishing systems can expand or be modified, and they’re never stuck at one speed or inextricably linked to every other process.

The earlier you can see automated finishing systems in action, the better. Even if you don’t ultimately choose an IntelliFinishing System, you are likely to make a more intelligent final decision, and you’ll certainly learn something.

Many of the systems we’ve installed are highlighted on our website in video clips. All of those systems often allow us to bring visitors. We also have many other systems that may be very similar to your needs that we haven’t captured on camera.

To learn more and see if there’s a compatible system you can check out to begin your own journey toward the perfect automated finishing system, contact us today.

Those with experience in manufacturing understand the bottlenecking that can occur during the finishing stage. The process of painting parts and components seems to crimp workflows and create delays that throws a wrench into your production schedule. Greater efficiency is crucial for achieving a fast and agile operation and finishing without compromising quality. IntelliFinishing’s advanced technology can help optimize the way you finish, providing consistent, exceptional quality so that your business can remain competitive.

Do More with Smart Technology

Old paint systems are out; new smart controls are in! As the name suggests, smart controls are advanced, digital tools that allow users to monitor and track parts, as well as provide insights to identify problem areas within a finishing process. Technology can pinpoint each part as it moves along the conveyor, as well as logging its weight, description, current process, previous process and the specified finish color.

Powerful Data For Maximum Efficiency

Smart systems provide a treasure trove of useful analytics. You can utilize this valuable data to identify bottlenecks and optimize your process. An intelligent system can also generate production reports that you can review, print, share, and evaluate. It logs historical production and process data so management can use the resulting reports to compare shifts, schedules, processes and the work of employees.

Recipes Made Easy

Applying a finish is much like baking a cake or cookies. It starts with having a desired recipe for the part from pre-finish steps, through paint, and ultimately to post finish steps such as cure, cool down and unloading. However, not every part finished should have the exact same recipe for optimal finishing. With a flexible automated finishing system, formulating, changing and applying recipes is as easy as a few keystrokes when using smart HMI controls – making it far more efficient than traditional paint and powder coating systems that rely on monorail conveyors or even power and free conveyors. An operator can input and review recipes on an intuitive display screen, and ascertain information such as Process Times, Production Rates, Order Status, Specific Parts per Carrier, Average Parts per Carrier, Load/Unload Efficiency, Blast Timing and Pressures, Wash Stage-Trends (temperature, pressure, titrations, duration and processes applied), Dry Oven Trends, Prime & Top Coat Trends and Cure Oven Trends. The system helps to identify errors before problems arise. For example, if a stage in your production list fails to meet the parameters of the recipe entered, smart controls flag it so you can remedy the issue before a finish has been applied. 

An Optimized Finishing Process

Smart controls make finishing fast by allowing multiple parts to be painted on a single system. Users can key in recipes that can be specific down to the part, and the system allows tracking of individual components. With IntelliFinishing, not only will your operation enjoy a fast and optimized process, but the system also ensures quality by reviewing connected environmental conditions, particularly helpful for CARC processes, or integration with other ERP or database driven systems.

Historically the finishing process has sometimes been a problem area in a manufacturer’s workflow, but not anymore. Through the integration of smart controls, IntelliFinishing stands out from competing systems, offering a faster way to convey parts through paint stations, maintaining exceptional quality and accumulating data to make your operation the pinnacle of efficiency. To see our smart controls in action, click here!