IntelliFinishing - The Only Lean Paint System

IntelliFinishing Powder Coating and Liquid Paint Systems are LEAN

Modern Metals Magazine

Finishing systems have never been thought of as lean…or green. In fact, some lean experts believe that paint is the one production area in today’s factories that cannot conform to the lean methodology. IntelliFinishing is the first of its kind to introduce LEAN thinking into the finishing process. We do this by eliminating wastes within the manufacturing process. See the entire of list of reasons an IntelliFinishing system is lean below. 

The secret to making a profit is building a system that is scalable, while handling a diverse size and quantity of parts. With IntelliFinishing, you can make your finishing system lean with point of use access to your factory floor. Also, decrease the amount of valuable floor space, while cutting energy and chemical costs, compared to the traditional monument systems. 

Here are a few of the improvements achieved with IntelliFinishing's systems:

  • Removed 1,000 feet of chain after replacing power & free with IntelliFinishing
  • Reduced WIP by 50%
  • Doubled throughput
  • 3 shifts to 1 shift
  • Decreased injury claims and turnover 

Read how Caterpillar made their paint process lean in Modern Metals Magazine.

Elimination of Wastes with an IntelliFinishing Complete Finishing System

Lean is a systematic method for the elimination of waste within a manufacturing process. IntelliFinishing provides automated powder coating and liquid coating systems that eliminate waste in the following ways.

Transportation Wastes Icon

Transportation Waste

Transportation waste is the unnecessary movement of people or parts between processes or from one location to another. 

An IntelliFinishing system reduces transportation waste:

  • no more batching = reduction in WIP
  • recipes (process speeds and times specific to the part)
  • independent zone and carrier control (systems are designed and implemented allowing control of individual carriers to start and stop independently throughout the system)
  • single piece flow
  • reduce downtime – 1% or less due to minimal conveyor maintenance
  • point of use – independent transportation of product from previous operation to finishing to next operation
  • no wasted movement – friction-driven conveyor only moves when part is present (unlike continuous running chain conveyors)
  • reduction in floorspace
    • no wasted space on return chain
    • use of shuttles & deadhead turns
    • layout flexibility 

Inventory Wastes Icon

Inventory Waste 

Inventory waste is the raw materials, work in progress (WIP) or finished goods stock that is held, not having value added to it. 

An IntelliFinishing system reduces inventory waste:

  • reduce WIP using single piece flow 
  • accumulation buffers can be decreased
  • no need to batch because of recipes
  • reduce number of parts to be reworked due to no risk of dripping lubrication because there is no chain (reduced number of defective parts)
  • reduce bottlenecks
  • IntelliFinishing customers use reports and tracking to determine the root cause of a bottleneck
  • downtime (scheduled or unscheduled) is reduced because maintenance of a carrier/trolley can be performed on a spur without stopping production

Motion Wastes Icon

Motion Waste 

Motion waste is the unnecessary movement of people, parts or machines within a process. 

An IntelliFinishing system reduces motion waste:

  • lift for ergonomic loading of parts
  • conveyor (chain) does not run constantly
  • processes don't run continuously, only when a part is present
  • small footprint (decreases amount of employee movement)
  • layout flexibility (manual procedures, like masking or labeling, can be located in close proximity)
  • less maintenance required compared to monorail and power & free
  • manuals and operating instructions located at the HMI
  • smart controls (quickly identify part locations anywhere in your system) 

Waiting Wastes Icon

Waiting Waste 

Waiting waste is the act of doing nothing or working slowly while waiting for a previous step in the process to be completed.

An IntelliFinishing system reduces waiting waste: 

  • no production gaps or empty hooks (employees aren't waiting for parts)
  • minimal (1% or less) unscheduled downtime decreases cost of employees waiting for production to resume
  • recipes (process can be pre-programmed for incoming parts)
  • ERP integration and product scheduling (allows operators to load parts quickly)
  • eliminate bottlenecks (independently controlled zones)

Overproduction Wastes Icon

Overproduction Waste

Overproduction waste is making products in too great a quantity or before it is actually needed leading to excessive inventory.

An IntelliFinishing system reduces overproduction waste:

  • decrease your defect rate by reducing part contamination (no need to compensate for quality issues due to dripping lubricant)
  • consistent quality (independently controlled zones mean process times are consistent)
  • easily integrate to point of use (less risk of damage to parts because of less handling)

Overprocessing Wastes Icon

Overprocessing Waste 

Overprocessing waste is adding more value to a product than the customer actually requires such as painting areas that will never be seen or be exposed to corrosion.

An IntelliFinishing system reduces overprocessing waste:

  • recipes determine:
    • How much time each part family spends in a process instead of having the same process time for all parts
    • The number of wash stages a part goes through (skip degreasing when a part does not require it)

Defects Wastes Icon

Defects 

Defects are products or services which are incorrect the first time and require repetition or correction of a process. 

An IntelliFinishing system reduces defects waste:

  • reducing part contamination (no need to compensate for quality issues due to dripping lubricant)
  • consistent quality (independently controlled zones mean process times are consistent)
  • easily integrate to point of use (less risk of damage to parts because of less handling)
  • eliminate defects due to flash rust that are frequently caused when employees stop a monorail conveyor line for breaks
  • reduce damage caused by part sway (gradual acceleration and deceleration)

Resource Wastes Icon

Resource Waste 

Resource waste is the non-efficient use of your lights, heat and power and the wasted potential of people. 

An IntelliFinishing system reduces resource waste:

  • reduce the number of employees required to operate system (replacement of monorail system condensed three shifts to one shift)
  • recipes determine
    • how much time each part family spends in a process instead of having the same process time for all parts
    • the number of wash stages a part goes through (skip degreasing when a part does not require it)
  • reduce energy consumption with insulated ovens and washers (49% reduction in energy usage)
  • ERP integration and product scheduling (allows operators to load parts quickly)
  • point of use – independent transportation of product from previous operation to finishing to next operation (reduces amount of material handling needed)
  • reduction in floor space
    • system is built to "right-size" from the beginning
    • due to elimination of return chain
  • eliminate bulb turns with shuttle or dead head
  • modular system allows for easy expansion
  • downtime (scheduled or unscheduled) is reduced with our system because maintenance of a carrier/trolley can be performed on a spur without stopping production
  • less maintenance required compared to monorail and power & free
  • retained asset value is higher than traditional systems (IntelliFinishing system typically has 85% retained asset value because it's re-deployable)
  • installation in half the time (modular washer and modular oven fabricated off-site)


Contact Us

Complete Powder Coating System

Powder Coating System

Complete, automated powder coating system offering flexibility for a variety of part sizes, thicknesses and process times.
friction-driven chainless conveyor

Chainless Conveyor

Our chainless conveyor is a unique alternative to power & free offering additional options and features traditional systems can't provide.
IntelliFinishing 3D System Animation

Finishing System 3D Demo

A complete finishing system with smart controls that allows carriers to move independently in both speed and direction.

view all videos

View All Videos

The best way to understand the unique features an IntelliFinishing system offers is to view our complete set of videos.

Google+ Blog LinkedIn Vimeo YouTube Twitter Facebook
Join our email list Subscribe

Industry Partners

Kasa Controls and Automation Midwest Finishing Systems IntelliTrack