IntelliFinishing presents at Caterpillar’s Suppliers Conference

IntelliFinishing recently attended and presented at the Manufacturing Equipment Suppliers Conference hosted by Caterpillar.  This conference was limited to Caterpillar’s preferred  equipment suppliers. IntelliFinishing is a preferred  provider of turnkey finishing systems around the globe.

IntelliFinishing was one of three suppliers who was asked to share information to the group about their collaboration efforts with Caterpillar.  Doug Oliphant, Vice President of IntelliFinishing, provided a presentation on IntelliFinishing’s energy study of an existing paint system.  “Unfortunately old paint systems are not like classic ’57 cars,” Doug stated. “At some point you are better off replacing with new technology that saves energy, reduces WIP, decreases downtime, and improves quality. Your cost per part will be lower and your total cost of ownership is less with an investment in a system that is re-deployable, expandable and energy efficient.”

The study by IntelliFinishing included automated paint system layout ideas to replace an existing system. The new layout would reduce floor space by 42% and decrease energy costs in the process equipment by over 50% compared to the traditional system currently installed.

 

IntelliFinishing Unveils ‘Lean’ Finishing Technology at FABTECH 2010

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Media Contact:

Keith Daw

Diamond Three Public Relations

816.686.9410

keith@DiamondThree.net

IntelliFinishing Unveils ‘Lean’ Finishing Technology at FABTECH 2010:

IntelliFinishing is more than a company. It’s the namesake of a product that is the direct result of extensive research to devise a finishing solution addressing specific challenges within a large equipment manufacturer’s finishing process. Their need for a re-deployable finishing system capable of handling both very heavy and small parts on the same conveyor while incorporated within a lean environment, created a necessity for something new. Read more

Why invest in a new finishing system?

It is often hard to justify replacing what isn’t broken, or upgrading what has worked so well for decades. Why invest valuable time or money in a project?

As the new kid on the block, IntelliFinishing gets asked these questions frequently. For generations parts have been finished the same way by everyone from car manufacturers to job shops. Everyone is accustomed to consistent speed, chain driven systems that get the job done. After all, nothing has changed on traditional monument systems; they are reliable and proven.

Our response is usually to demonstrate the differences in our system from the “standard” way of life.

– We can move a carrier forward and backwards, without affecting others on the line

– Shuttles in our system can move parts sideways to avoid space eating loops

– Lifts can transport parts vertically for loading, unloading, or to move to a mezzanine level without a long incline

– Our controls can track and identify every part, on every carrier, through every part of the process to help track quality and maintain consistency

– The entire modular system can be assembled in a fraction of the time, in a smaller footprint, and can easily be added to later without disrupting production

Sometimes the light comes on quickly in our customer’s eyes, other times it takes time for the bulb to warm up and flicker on. As they realize the potential for improved quality and efficiency in a system that can grow and adapt in-line, the “ah-ha” moment is not far behind

No longer is batch processing or a single line speed necessary, as we can accelerate or decelerate individual carriers based on the recipe for the parts on the load. Also being monitored and controlled are all of the process equipment such as ovens and washers. If there is no carrier being processed by the washer, why is it on? Using the IntelliFinishing system our customers save an average of 40% on their annual utilities costs.

It may take a bit of time, but we are patient. We are ready to visit with you about your particular needs and circumstances, and how we can design a system specifically for your facility and production requirements. Think past the way it has always been done, and look forward to the way it is being done now. IntelliFinishing is changing the face of finishing systems across the world.

And we have plenty of light bulbs.

Part I: The Walls Are Closing In

Part I of Solving Our Customer’s Challenges:  The Walls Are Closing In

Going beyond our technologically advanced components and space saving design, a large part of our job at IntelliFinishing is working with our customers to solve their problems and challenges. There are usually a few key hurdles that lead a customer to consider purchasing a system or renovating their existing setup. As part of a four part series, we will look at the specific challenges one of our recent customers faced, and the solutions provided by IntelliFinishing.

The first concern for our customer was how they were going to replace their existing manual paint shop with an automated, state-of-the-art IntelliFinishing system in the same space, which only measured 74 feet across and 55 feet deep.

IntelliFinishing’s solution to this challenge was to make use of our unique conveyor design that allows our product carriers to flow forwards and backwards, independent of other carriers in the system. This allowed us to “dead head” or “spur” into areas like an inspection platform and a washer to reduce space. In the curing oven we used our variable speed drives to speed up or slow down dwell times based on the part recipe. This, along with in-depth part tracking, allowed our curing oven to be much smaller in size, while allowing the wide range of flexibility required by the variety of parts being coated. Finally, since our system is truly decoupled, we could incorporate short motor breaks for inspection and masking areas without affecting the effective line speed throughout the rest of the system.

As a result of our innovative equipment and controls, IntelliFinishing was able to successfully design a system that met all of the customer’s goals while not exceeding the 4,000 square foot area of the outdated manual system. Find out how our use of shuttles and lowerators can reduce your system footprint while maintaining or exceeding your expectations for performance and flexibility!

Read Part II

Read Part III

Read Part IV

Learn about Lean at Midwest Coatings Seminar 2013

MCS-thumbnailAre you new to the industrial coatings industry, or want to learn more about Lean Manufacturing and how it can be applied to your manufacturing process? Join us at the third annual Midwest Coatings Seminar on August 8th to network with other manufacturers and suppliers in the area, learn about how to implement lean, and see a live demonstration of IntelliFinishing’s new spinning tube conveyor technology.

This year’s presenters include Brad Muir and Gary Conner of Technical Change Associates who will be discussing Lean as a growth strategy. Experts in the field with over 40 years of experience, Brad and Gary will cover the tools and techniques to successfully implement lean into your manufacturing and finishing processes.

Following this interactive presentation, you will have two options.

Option 2 – Improve Production Line Gaps, presented by David Underhill of IntelliFinishing. Learn how production line gaps can be improved or eliminated with the right conveyor and controls. David has over 30 years of experience in the finishing and conveyor industry and will touch on topics of inventory problems, reduced production throughput, and other negative effects of production line gaps.

Option 1 – Improve Communication by Removing Waste presented by Dan Stutterheim, CEO of Kasa Companies: Lean.  In manufacturing, it means reducing waste, specifying value from your customer’s perspective, and allowing it to flow.  Can you apply these Lean Principles to the way your organization communicates? Absolutely. Long emails will be reduced to sentences.  You can communicate your vision, your plan, and your instructions in a way that everyone understands the message and acts upon it appropriately.  Reducing waste in communication is based upon learning the six personality types and a new concept of communicating called the Process Communication Model (PCM)®.  Applying these concepts will lead toward a trusting and efficient workplace where everybody understands the intent of your message and acts upon it appropriately.

If you are able to stick around for dinner, IntelliFinishing will host a BBQ at their main facility just a few blocks from the seminar. The informal dinner is a great opportunity to visit with other attendees or ask the presenters in depth questions relating to your specific situation.

To learn more, register for the event, or view the schedule, point your browser to www.leanfinishing.com.

What is a Recipe-Based Finishing System?

Recipe Based Finishing System

With a Recipe-based system, carriers with dissimilar parts can run back to back and each can be treated differently based on the process data entered into the system as a “recipe”. There is no longer a need for batching your whole line with like parts to get quality.  When you enter commands or process instructions for each part family or group of characteristically like parts each time that “recipe” is selected at the loading point all of those like parts will receive the same process.  If you have a different carrier of parts, all the operator needs to do is select that recipe at the load area HMI screen. When that carrier gets to a process area, the system will automatically run the selected process for that part family.

In the Wash:

The recipe entered allows for different types of metals or parts with different pretreatment requirements to each have their own unique wash Recipe.  For example it is possible to remain longer in a section, skip a section, or bypass the whole wash.  If you have changes in your wash process due to extra dirty parts or changes in chemicals requiring your system timing to be different all you need to do is update the recipe.

In the coating application:

In the coating application area, displays show the process for each part coming through, where to apply the coating, which color, and any special instructions unique to those parts.  For applications with masking options, the work instructions show pictures of where to apply masking, caulking, or any other special procedures.

In the cure:

Thick parts and thin parts do not need to be run separately in a batch mode.  With a recipe based system, parts that have 20 minute cure time and parts that have a 40 minute cure time can be run on the line at the same time.  You will no longer over-bake your thin parts just to make sure that your thicker, longer curing parts get cured as desired.  Ovens can adjust temperature, air turns, and cure time depending on the parts loaded on the system.

A “Chainless” Power & Free Conveyor?

A “Chainless” Power & Free Conveyor?

Construction

The IntelliFinishing conveyor is a bolted together floor supported system with friction driven trolleys on a rotating tube instead of a chain to drive the system.  Due to the bolt together construction, this conveyor can be easily modified and moved and can be installed in half the time of conventional conveyor systems. We offer a variety of conveyor models with the ability to handle different weight categories which enables us to further customize a system to fit your specific process needs

Maintenance Free

With our Chainless Power & Free there is no maintenance or mess of keeping the conveyor constantly lubed, additionally there is no mess or contamination of lubes, oils, or grit falling onto the parts processed.  All of the moving components in the conveyor system are lubricated for life.

Operation

Each conveyor section has a separate motor which allows individual sections of the conveyor to speed up a part in a process area or slow a part down based on the part recipe. The separate motors also turn off and on the individual conveyor sections when there is a part present making this system more energy efficient because the full system isn’t always running, only the process areas being used at the given time. Additionally, the Chainless Power & Free conveyor has a much quieter operation due to no metal on metal noise.

 

Capabilities of the Conveyor (partial list):

  1. Change processes or destinations of products with immediate system response
  2. Set up in-line speed changes
  3. Run trolleys both forward and backwards
  4. Stop a carrier for processing without stopping the entire line or holding up production
  5. Easily incorporate vertical lifts and shuttles to move parts to another line without unloading
  6. Negotiate inclines and declines
  7. Accumulate loads in line
  8. Have both driven and non-driven lines on the same system
  9. Dip the conveyor into tanks
  10. Run the conveyor through Dry-off and Cure Ovens up to 450 degrees
  11. Highly configurable and modular

Part I: Changing the “Game”! – Improving Paint System Design

Part I: Changing the “Game”! – Improving Paint System Design

IntelliFinishing has had a great start in the introduction of our new industrial paint system. We’ve had a fantastic response from numerous companies that do industrial coating. I think our favorite comment so far has been, “Wow! Seriously,…I can do that?” It was a great “ah-ha” moment.

IntelliFinishing is really changing how people think about finishing systems. We know it is hard to pull your mind from the way a finishing system has always been; stationary, single speed, single direction, take it or leave it type systems. Once you understand the IntelliFinishing system, it will shatter your preconceived notions and known limitations of what a paint finishing system has been. 

Here are some highlights from the Paint System Designs we’ve created:

  1. Opened up three bays of floor space, that’s 1200 sq. ft., utilizing our advanced conveyor and system technology, while also adding additional process equipment.
  2. Fit an entire Powder Coating system; load/unload area, 3-stage washer, dry-off oven, cooling areas, powder booth, cure oven and bias banking into a 2,540 sq. ft. area to process a 19’ long part.
  3.  Designed a complete liquid and powder system as one singular system; giving the customer ultimate flexibility to run their ever changing parts. When their customer demand needs more liquid painted, it wasn’t a problem; and if that afternoon they needed to run parts through powder for another customer, it could all be done on the same system.

We have had a fantastic time developing these paint system designs and implementing them for our customers.  It has allowed us to share our knowledge and excitement about the IntelliFinishing system, as well as expand our technology to meet the ever changing needs industrial finishing companies face, and trust us; there have been some interesting challenges!  The solutions we have developed due to the flexibility of our system have brought about a number of “ah-ha” moments from our customers as their conventional understanding of conveyors and finishing systems is quite suddenly thrown out the window.

Give us a call at 888-886-6363 or email us at info@intellifinishing.com and let us know about your challenge!

Rachel Snyder

Engineering & Sales Coordinator

IntelliFinishing

Part II: Changing the “Game”! – Improving Paint System Design

The capabilities of the IntelliFinishing turnkey system are numerous, as are the features this system has.  Having the ability to move parts in individual areas forward and backward, as well as moving at different speeds, without affecting the rest of your line has been a key element in understanding the savings benefit of the IntelliFinishing System.  Not only does this save in floor space usage, it also saves in energy costs, and chemical and water usage.

Imagine if you could only drive your vehicle in the forward direction, at one speed which is based on the vehicle driving in front of you…this scenario limits your abilities to get where you want to go. So why have a finishing system with that same limitation? Give us a call at 888-886-6363 or email us at info@intellifinishing.com. We’ll take the time to talk to you about your needs, answer any questions you have about the IntelliFinishing System and design a system that meets and exceeds your expectations.

A Plan for Every Part

A Plan for Every Part©

Ever wish you had a different finishing line for every type of part you have to paint or powder coat? Large heavy parts take more time to process than small thin ones. Some parts require additional masking and others don’t. Different chemistry is required for different types of metals… the list seems to be endless.

IntelliFinishing has presented to a variety of audiences recently and manufacturers are impressed with the “Plan for Every Part©” technology. Each item you process gets the best finish available, just like the system was built specifically for that part.

Unlike traditional finishing systems where the system is built for your longest or heaviest part, which results in over-baking of other parts; the IntelliFinishing finishing system provides capabilities that are unmatched in the finishing industry.

With conveyors that move load bars of parts at varying speeds which are based on the parts’ unique size and material, an IntelliFinishing system offers capabilities in ONE LINE that would take MULTIPLE LINES for traditional systems. Customers have been amazed at what can be accomplished with layouts that are not limited by a one-way, one-speed conveyor.

The IntelliFinishing system is not for everyone.

  • Do you finish a variety of sizes of parts?
  • Do you finish parts that are made from different materials?
  • Do your processes for finishing ever change?

If you answered YES to any of the above questions, then you may want to see how an IntelliFinishing system is rocking the world of finishing. Contact us at info@intellifinishing.com.