In this video Bill Dunn, CEO of Manufacturing Resources International, Inc. (MRI), explains why he is extremely satisfied with his IntelliFinishing automated finishing system.
From a manpower standpoint, from a capacity standpoint, from a quality and consistency standpoint, I don’t think there’s anything better.
Interested in an exceedingly flexible, less costly to operate automated finishing system with proven technology? Contact IntelliFinishing at 785-309-0356 or info@intellifinishing.com.
Automated shuttle finishing systems using IntelliFinishing’s unique friction tube conveyor can deliver considerable benefits to manufacturers with very specific needs that standard finishing systems can’t handle.
IntelliFinishing helped several companies recently solve their unique challenges in finishing by using friction tube shuttles within their total system to accommodate large heavy parts and to fit within small building footprints.
Here are three examples that demonstrate the flexibility of the IntelliFinishing system using shuttles instead of large radius turns.
IntelliFinishing recently installed a powder coating system featuring two shuttles for Manufacturing Resources International LG-MRI, manufacturers of outdoor liquid crystal display screens (LCDs) in Alpharetta, GA. They use their IntelliFinishing system to powder coat the frames, back panels, stands and other parts for their outdoor, high resolution, high tech, extremely weather-resistant, LCD advertising displays. Typically, components for these items are between eight and ten feet long, but some may extend to twenty feet in length for their largest options. While the parts are usually lightweight sheet steel, stainless steel, or aluminum, the system can support weights up to 1,000 lbs. per carrier – useful for the way MRI maximizes part density on their system.
The MRI system features a 20-foot carrier and shuttle on the left-hand side of the system for transporting products from the load area, through an automatic and integrated sliding door into their unheated and uncooled added manufacturing space where automatic washing, dry-off and curing processes occur.
Parts on the carriers move through a multi-stage wash with recipe options that define the timing and pressure settings, then into a dry-off oven – also with variable timing options.
Once dry, the parts move back into the main building and to their reciprocator equipped automatic powder spray booth. After coating, the parts are transported via a middle lane shuttle back out through another set of automated building doors to the added building and into one of their two final cure ovens on either side of the shuttle. Once cured, items then move from the ovens, via the same middle shuttle back through the automated doors to a buffer area where they can cool and finally again back to the shuttle to the load/unload lane. The load section of track also includes an integrated lift to make part handling easy and safe.
Not all of MRI’s parts require finishing. They also use the system to just wash and dry metal parts that will be unfinished in the final assembled monitors. This greatly improves the overall quality of their sets by removing unwanted dust and oils – a process they used to do by hand.
Interestingly, MRI also uses their cure ovens, on occasion, to harden some of their aluminum parts – a process called precipitation. They simply load these parts, wash and dry them and then store them at desired temperature overnight in their cure ovens. Truly, a unique application demonstrating just how flexible their IntelliFinishing system is for them!
Located in Springfield OH, this OEM manufactures forklift accessory equipment. The majority of their forklift accessories are twelve feet long or less but a few can be as long as 23 feet and weigh up to 5,000 lbs. With the complexity of the product dimensions and weight requirements along with a very small, under 10,000 square foot of space available (66’ x 149’) to work with, they needed a custom shuttle system to fit the space. They use their system to apply a liquid finish to their parts. Their system also features two shuttles to fit all sizes of parts they manufacture but with a twist.
Depending on the size of the part, there are different flow paths through the system. This is caused because one of the two shuttles allows part only up to about half the size of the other shuttle. Since the majority of their parts are at or below 12-ft. in length, after being loaded in the loading lane, carriers proceed to the left onto a shuttle sized for up to 12-foot parts. This shuttle moves laterally from the loading lane to line up with the wash booth lane. From there the carrier can back up off the shuttle moving from left to right and go through a multi-stage automated wash booth lane. After wash, carriers flow onto a larger right side of the system shuttle and into one of their two liquid spray booths. After being coated, items back out of their respective booths and onto the larger shuttle again. The shuttle transports the parts laterally again up to the cure oven lane where they leave the shuttle and flow into the final cure oven. At this step, each carrier can have its own oven timing setting to maximize force cure quality, while eliminating chances of under or over curing products. Cure time is controlled by the system recipe selected at load per carrier. After curing, the carriers move once again to the first shuttle and laterally again up to the unload lane for final unload and the consequential return of the carrier via the large secondary shuttle back to the load area lane on the other side of the system.
For the products over 12 feet in length, the carrier path/flow is different. Larger items are loaded within a manual wash enclosure at the bottom right-hand side of the system. This wash area is to the right of the right-side, large-shuttle rather than in the usual middle lane loading area. The manual wash was installed to offer a wash option for their significantly larger but rarer big parts while keeping the size of the automated wash within the desired footprint. After the manual wash, the long parts are shuttled to the left onto the large shuttle and laterally into each piece of process equipment including transport to the longer of the two spray booth options they have available. After finish, long items still proceed by the large shuttle to the system centered force cure oven, except they don’t flow all the way through the oven like the smaller parts do. They “park” just inside the oven for the required recipe time for these larger and thicker/heavier items – and then are sent backward to the large shuttle again before transport up to the unload lane for their final unloading. In other words, the large parts can still be processed but they never use the small left side shuttle and hence we were able to keep the system within the tight footprint available.
Load Trail had a significant challenge finishing its agricultural trailers. The trailers range in size from 24 to 53 feet in length and weigh up to 10,000 lbs. To help them solve the problem of powder coating these trailers and to streamline their finishing, we installed a dual shuttle system at their Sulphur Springs, Texas facility.
Their conveyorized system features nine load lanes that run above their nine weld cells, enabling trailers to load directly onto the system just above their final weld process. Trailers, from 24 to 53 feet in length are then transported directly onto a large primary shuttle to move them laterally to as well as in and back out of each process.
As carriers transport trailers from the shuttle into each piece of process equipment and then backward back to 
the shuttle, it allows for a massive system, but one that still saves space because it does not require any bulb turns or return sections of chain track.
Processes on Load Trail’s shuttle system include automatic and manual shot blast booths, automatic multi-stage cabinet wash booth, a dry-off oven, several final prep and quality control stations, prime and topcoat powder booths, multiple final cure ovens, dual unload stations on either side of the main shuttle, and a carrier return shuttle for the empties back to and above the original nine weld and loading cells.
At IntelliFinishing, we take pride in providing the most flexible, modular, and trustworthy, custom automatic finishing systems that can address the unique finish, parts, and footprint needs of our customers.
If you’re interested in seeing any of these shuttle systems to get an idea of how our solutions may benefit your operation, contact IntelliFinishing today to discuss a site tour (when conditions allow) or simply to learn more. Our number is 785-309-0356.
Manufacturing Resources International designs, engineers and fabricates BoldVu® LCD displays, maintaining the industry’s largest install base of outdoor LCDs with deployments in over 50 cities around the globe.
However, MRI had one central challenge – the company’s powder coating was outsourced, leading to critical inefficiencies.To solve this problem, MRI turned to IntelliFinishing, which provided an automated powder coating system for the company that elevated every aspect of MRI’s operations.
Owner Bill Dunn said MRI’s problem was a simple, yet weighty one.
Because the powder coating of critical parts for the company’s LCD displays was outsourced, Dunn said wait times for parts to return to MRI’s shop floor were becoming excessive, and the quality of the finished product wasn’t consistent with the expectations of MRI’s client base.
“I was looking for a way to take my powder coating in-house,” Dunn said. “My clients have high quality standards, and we needed quicker turnaround. My vendors providing powder coating had a lot of quality issues, and it was taking at least four weeks for parts to return to our shop floor.”
Another obstacle was the size of the parts MRI manufactures. Many total about eight feet in length, with some reaching up to 20 feet long.
Simply put, MRI needed a faster, more consistent finishing system, including capabilities for a powder coating line and paint conveyor line, that operated on a tight footprint capable of being integrated into their existing facility.
To meet MRI’s unique needs, IntelliFinishing designed, engineered and built a high-quality automated finishing system with shuttle capabilities.
The system can handle parts up to twenty feet long by five feet wide by eight feet tall, and up to 800 pounds per loadbar.
This flexibility allows parts of all sizes to move through their three-stage wash, energy-efficient drying ovens, through a powder coating booth and into one of two cure ovens.
The system includes two shuttles, and each passes through system-integrated sliding doors to move from inside the main building into an adjacent space constructed for the wash and oven equipment.
To facilitate loading, MRI decided to add an integrated system lift. They are able to hang up to ten of their product frames, each in a horizontal position and suspended from one another to maximize part density. As each frame is attached, they lift the hung frames just a few inches and then attach the next frame. Once all frames are attached, the lift takes the whole set of parts to system height inline with the conveyor and then moves the set of frames to the first shuttle for transport to the wash lane on the other side of the system.
Not only does the system give MRI the finishing quality and volume capacities they were looking for, they also use the system to thoroughly clean and dry their critical non-finished parts. This was a process that was previously done by hand, thus saving a ton of labor and providing much more consistency and cleaner parts for their LCD screens.
Finally, MRI also uses their curing ovens on occasion to harden selected aluminum parts by cooking them overnight at high temperatures. This is called precipitation hardening.
The addition of an IntelliFinishing system has brought a wide range of benefits to MRI’s operation, including:
“I looked at several traditional systems when I considered IntelliFinishing. Although IntelliFinishing’s initial price was a little higher than the alternatives, when you consider it from a cost-per-square-foot basis, as well as for its ability to do far more than the other systems, it was actually the least costly for me, saving me a ton of room for other processes,” Dunn said. (see Bill’s complete thoughts on his IntelliFinishing system here)
“I use the IntelliFinishing system as a closer for when prospects for our LCD monitors come to look over our plant. Just like us, it’s high tech and high quality.”
Are you still operating under the old automated finishing system paradigm?
Ever since Henry Ford developed the assembly line and its paradigm was applied to automatically finishing parts, the basic thought process has been the same…
Segment all parts that need the exact same finish recipe and create an automatic finishing system to do that single recipe.
For this type of automated finishing system, a monorail continuous chain system or equivalent is great!
But many manufacturers and custom coaters need to paint many different type parts that all require different part recipes. This is easy to do with any manual or batch system, but volume per day is limited, and it has been difficult with automated, chain-based systems.
With the advent of power and free (P&F) chain-based systems, recipe flexibility was enhanced, and parts could be routed to different processes, stopped, sped up or slowed down per drive and chain.
Still, these systems lacked some level of needed flexibility. For example, let’s suppose you have a power and free system that routes some parts through an inline shot blast. In general, that part of the chain will be configured to run at a certain feet per minute. It should be possible to speed up or slow down that loop of chain, but it would not be likely that a company would load something that requires 5 fpm in the blast right after another item that can speed through at 20 fpm – the manufacturer would still need to segment the parts that require more time in the blast from those that require less time. Similar examples could be made for other pretreatment processes when parts are in the wash, in the booth, and in dry or cure ovens, etc.
With a recipe-based system, carriers of parts moving through a system loaded with dissimilar parts per carrier can run back-to-back. Each carrier can be treated differently based on the process data entered into the system as its “recipe.”
There would no longer be a need for batching your whole line or long segments of your line with like parts to get quality. Work in progress would be reduced, and scheduling of work on the finishing system would be greatly simplified.
With an IntelliFinishing system, users enter commands or process instructions for each part family or group of similar parts, creating a “recipe.” The recipe is selected manually or automatically using scanners or other technology at the loading point for that carrier. All of those like parts on that carrier will then receive the same process. If you next have a different carrier of parts requiring a different recipe, all the operator needs to do is select that recipe at the load-area HMI screen or use their integrated scanner. When that carrier gets to a process area, the system will automatically run the selected process for that part family.
So, what does this mean per typical finishing process?
Shot blast recipes typically vary by the speed of the product though the blast and/or the intensity of the shot blast system itself. Either or both can be integrated into a recipe set of options. For example, one customer of IntelliFinishing typically runs his blast at 5 fpm. A 10 ft carrier full of parts or loaded with a single large part can then be shot blasted in about two minutes, plus travel time to the shot blast and travel time out of the shot blast area. But, with his IntelliFinishing system, he can change the speed of the carrier through his blast as needed, and he has recipes that include 8fpm, 10fpm, 15fpm and even 20fpm, etc. Even relatively lightweight gauge items can now be run through his blast at the 20fpm speed without damaging the metal. This customer even includes a recipe for some extremely dirty/rusty parts that routes the carrier to back up after the first pass in the blast and re-blast a second time.
Wash recipes allow for different types of metals or parts with different pretreatment requirements to each have their own unique wash process. For example, it is possible to remain longer in a section, skip a section, increase or decrease the wash spray pressure, or even bypass the whole wash based on the recipe. 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 your recipe. Since chemical companies are constantly improving their products, the ability to use a recipe means you can take advantage of these new products and no longer be locked into the chemical recipe of the day when the system was created.
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. And, of course, part of the recipe is simply which booth or set of booths the parts should flow to so that efficiencies are maintained. For example, on IntelliFinishing Systems, it’s common to have dedicated booths for the most common colors that rarely get changed, but other booths with quick-change capabilities. Items are thereby always routed to the most appropriate booth and the need to segment and schedule parts by color is eliminated.
Thick parts and thin parts do not typically require the same amount of time for drying off or curing. Even color variation or different paints and powders may create the need to vary gel and final cure timing and/or temperature. 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 same system at the same time without affecting any other upstream or downstream process. In fact, it’s common with an IntelliFinishing system to run multiple lane ovens, so flexibility and throughput are each enhanced. Faster curing items can pass the slower curing items in the cure process, just like having a multiple-lane highway increases the speed of traffic through a city compared to single-lane options. And, 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 per carrier and system design options.
Maybe something leaner, with less transportation, system, and manpower waste?
Something that can operate with just-in-time efficiency?
Give IntelliFinishing a call and discuss your finishing needs with our representatives. We’ll honestly let you know if what you need requires our type of system flexibility or if a more traditional approach would be adequate.
By the way, if you found this article intriguing, watch this video of one of our customers explaining why they like their recipe-driven IntelliFinishing system.
There’s no better way to investigate this proven technology than by visiting one of our many systems. Make arrangements for a system tour by calling us at 785-309-0356 or emailing info@intellifinishing.com to learn more.
In this feature article, Finishing Systems & Statistics in Powder Coated Tough magazine, IntelliFinishing’s John Claman discusses basic statistical metrics and tools that may be useful in the finishing industry. Process, throughput and product metrics are some of the measurements covered in the article.
John’s main goal in this article is to remind owners/operators to occasionally review the basic understanding of statistics to possibly streamline their finishing operation.
Read the full article here.
Good question. It starts with knowing how much you currently spend and how much throughput volume you may need in the future. How much do you spend now on outsourcing your part finishing?
Many manufacturers outsource some to all of their finishing, be it powder coating or liquid finishing, because they want to leave it up to “experts,” don’t have space for a system, and desire to concentrate on what they do best, like fabricating and assembling final products. They could also have unusual or rarely needed parts that simply cannot be done on their in-house systems.
Let’s just assume you are outsourcing your finishing because your need for it started out small but has grown over time. At this point, you mainly do it because, “It’s what we’ve always done.” Maybe it’s time to start working on a business case that would let you know if you’re ready for your own system!
Let’s also throw some hypothetical numbers at this issue.
Imagine your outsourcing of finishing has grown over the years to about $1 million per year with local (or maybe distant) custom-coaters. How much money could an automated, in-house system save you per year that would justify the relatively large capital expenditure?
As a starting place, would it make sense that you would at least save the gross profit margin your custom-coaters are currently collecting from you? (For this article, we’ll ignore the fact that bringing finishing in-house is also likely to decrease total WIP, greatly decrease re-work, improve turn times, and save on transportation costs, too.)
Obviously, that gross margin varies depending on product, unique challenges, etc., but let’s sling a guess at it.
IntelliFinishing’s parent company (Kasa) operated a relatively large fabrication and coating company called KasaFab for many years before selling it to a local manufacturer.
Our former VP of that company still works for Kasa, and he said, “On small-quantity powder work, we would charge a pretty high margin of 60 to 65%. On large-quantity work, we would shoot for 50 to 55%.”
Now, maybe your custom coater doesn’t get as much margin as our former KasaFab operation. This might be because there are more competitors in your market. After all, KasaFab (now Vortex Fab) is the only large fabricator for at least 50 miles or more in any direction. It is in the middle of Kansas!
Meanwhile, I’ve also heard it said by longtime experts in the field that you should be able to save at least 20 to 40% by bringing coating in-house.
So, let’s start conservatively and imagine a savings of only 25% to represent the gross margin your custom coater is charging. This means a new automated system should save you at least $250,000 per year, assuming the previous assumption of $1 million per year being outsourced.
Depending on the types of product you need coated, even a relatively traditional monorail could be paid for in about two to four years for this amount of savings. After that, it would be savings that go to your bottom-line profits. Most simple monorail systems likely cost between $500,000 and $2,000,000, but this is entirely dependent on process requirements for pre-finish steps such as shot-blasting, washing, and dry-off ovens, as well as for the type of booths and cure ovens and specific conveyor requirements for the part dimensions and weight considerations.
However, for an IntelliFinishing System, it’s a little more complicated. Our systems are much more flexible than monorail systems in that we can accommodate processes for a much wider variation of parts. IntelliFinishing systems use a friction tube conveyor that allows for control of every section of track, so every carrier can, in effect, be given a different process recipe (video: www.intellifinishing.com/part-recipes).
We also have a sophisticated software control system to integrate each independently operated section of track to keep items moving as per the recipe, yet also keep carriers from bumping into each other. Consequently, the conveyor and controls are somewhat more expensive than monorail systems, but often highly competitive with power & free chain-based systems.
Therefore, most IntelliFinishing systems installed have cost between $1,500,000 and $10,000,000, with an average of about $3,000,000.
But, here’s the kicker! An IntelliFinishing System is usually way less expensive to operate. Here’s a link to an article we recently published that explains why this is the case.
Since any custom-coater you are likely to use is unlikely to have an IntelliFinishing System, any manufacturer who installs an IntelliFinishing system is very likely to save much more than just the gross margin.
If the IntelliFinishing technology makes sense for your company based on the parts needing finished or your volume, then the “$1 million outsourcer” example we have suggested could save up to 60% compared to outsourcing. Thus, $600,000 per year saved could finance a much more economical IntelliFinishing system very quickly!
Of course, there may be other considerations. Do you have space for a system? If so, great! If you’re unsure, talk to us. Our system often saves 25 to 40% in footprint depending on the nature of your parts and processes. If you need to build or lease a new space, you will obviously need to include those costs in your calculations, too.
Ultimately, this is just a first-cut calculation to begin the process of considering a new finishing system. If your calculus indicates you might benefit from a system, the next step is to start finding a vendor to draft up a layout and determine a budgetary or formal quote.
But, before you decide to go with any one system, I’d also like to suggest you figure out your likely actual costs of having and running a new finishing system. You should do this from the ground up. The costs would include system and building utilities, building lease or purchase costs, depreciation considerations, manpower to operate the system, possible restructuring of existing processes and flow, and, of course, paint or powder costs, maintenance, etc.
If you are ready to consider bringing finishing in-house and are wondering if an IntelliFinishing system might be a good fit for you, check out our website and watch a few of our videos, then contact us. We will be happy to help you not only figure out a potential system, but also to help you with your cost justifications.
Now May Be the Perfect Time to Invest in a New Finishing System
Choosing to upgrade your finishing system is always a massive undertaking – and the current period of uncertainty may make it seem even more overwhelming.
However, the current climate may be the perfect time to take the leap.
Why? Let’s dive in.
Why the Push Toward a New Normal Offers Exciting Opportunity
There are several central reasons why, even as the COVID-19 pandemic continues, investing in a new finishing system may be a strategic and valuable move.
An Upcoming Spike in Demand – And Pricing
First, many companies have put off key projects in the wake of the COVID-19 pandemic, opting to save money and focus on core aspects of their operation until a more settled “new normal” arrives.
However, this dip in demand has us here at IntelliFinishing, along with our system partners, raring to go.
We’re hungry to keep our staffs busy, and pricing could reflect that.
But this window won’t last for long. As the reopening picks up momentum, backlogs will start to grow once again, and pricing will level out to normal levels. As confidence in this march toward business as usual grows, those who chose to sit it out and go without key upgrades for the time being will be left facing higher prices and longer project installation turnaround times.
Get Prepared to Be Lean, Agile and Productive in the New Normal
In addition to this likely spike in demand coming down the pipe, investing in a new system now can better prepare your company to emerge into the new normal lean, agile and productive.
By closely examining and evaluating your facilities and ways to eliminate waste, you can emerge stronger than your competitors and ready to meet heightened demand.
Waste on finishing can include the outsourcing of finishing – an expensive cost that most “experts” say could be reduced by at least 30% if brought in-house. Further, with an IntelliFinishing System – due to our lower costs to operate – these savings could be over 60%.
Of course, each situation is unique and would require in-depth analysis, but why not check into bringing your outsourcing in-house? (More on this topic in the coming weeks!) You’d also likely see far less rejects and defects, a reduction in transportation costs, faster turn times, less WIP, and better finish quality.
Even if you currently have a finishing system or multiple systems, they are likely to be much more expensive to operate or fall short of optimal needs than a new system.
If you wander by your finishing system and see high levels of work in progress (inventory) stacked around the system due to the requirement to batch like items together because of the inflexible systems you own, you are wasting money and labor.
If your ovens and your chain flood your building with heat because of large part window openings and chain/carrier heat sink transfer, you are obviously wasting natural gas, as well as possibly electricity to fan or cool your facility.
If your current system can’t keep up with production or has a part window that limits your product sales, it’s time to consider something better.
And, finally, if you have or are considering a system that consumes a larger facility footprint than an IntelliFinishing System can provide, you are missing an opportunity to use that space for other revenue producing activities or to have a smaller facility that costs less to build, own or lease.
Why consider a chain-based automated finishing system that is inherently dirty, contributes to finish contamination, is difficult to adapt per part or to innovation, and is wasteful of energy?
Visit an IntelliFinishing System Yourself
Finally, with many employees and leaders working remotely, it could be a prime opportunity to visit a cutting-edge, IntelliFinishing flexible automated finishing system, powder coating system or liquid coating system in your area to get an idea of exactly how investing in one could benefit your operation.
Let IntelliFinishing Be Your Guide
At IntelliFinishing, we’re committed to helping you find the best solution for your unique needs and operation – even if that means not upgrading your system at this time or recommending something more traditional if that’s the best fit.
However, if upgrading to an IntelliFinishing Automated System can bring you real value and efficiency, this could be the perfect time to get to work.
To learn more, contact IntelliFinishing today.
Automated finishing systems are tremendous drivers of efficiency. However, there are often areas of improvement. Let’s explore how some traditional designs fall short in this area and what you can do to double your automated system’s throughput capacity.
Chained to Design
Traditional, chain-driven automated powder finishing systems are usually welded together and set to function at a certain line speed. Because of this, it’s difficult to expand the throughput and increase production. You could try to increase the line speed, but then you’d be increasing the speed of all the system processes. In most cases, that means disaster.
This approach would also bungle the final cure step, which is usually designed for a specific length of travel time through a certain range of the oven. Trying to speed that up would result in the entire process being incorrectly completed.
There are more optimal solutions.
Monorails Limit Expansion
Because most automated powder finishing systems are monorails, it’s impossible to just bolt on more oven capacity.
Similarly, one can’t simply attach a new wash loop or additional booths to a monorail. If you want to change the functionality or design and double the throughput, that typically means having to build a whole new system.
Again, it’s easy to understand why this isn’t the simplest or most cost-effective approach.
The Costs of Power and Free Systems
Power and free automated powder finishing systems are more flexible in their design. Additional system loops and spurs can be added, but there are still associated difficulties and costs.
Mating new P&F track can be significantly challenging and often leads to major downtime events. If the system is down, it’s obviously not producing anything, which leads to extra costs.
You guessed it – there’s a better way.
Enter IntelliFinishing’s Automated Finishing Systems
An IntelliFinishing automated finishing system is the perfect solution for having a modular, modifiable finishing system that can double its throughput.
The systems are built with more of an “erector set” design in mind. During the initial building of the finishing system, expansion points can be introduced to compensate for future growth in throughput needs.
Possible bottlenecks (usually the oven capacity) can be identified and assembled with track switches for the eventual addition of other loops in the system. This way, when there’s a greater need for a certain process, it’s easy to build out the new spur, add the additional process and tie the system back together with minimal downtime and relatively low cost.
Double Your Throughput with IntelliFinishing Automated Finishing Systems
These innovations are what make an IntelliFinishing system leaner, more cost effective in the long run, more cost effective to operate each day, and better able to meet many of the changes and innovations as systems -class company with unparalleled expertise in the powder-finishing industry. As your company and your needs expand, our systems will grow alongside you.
You can waste money on purchasing new systems every time you need more throughput, or you can upgrade to an IntelliFinishing system and work with our experts to find the best solution for your unique needs and future-proof yourself in the process.
To learn more, visit www.intellifinishing.com.
JR Custom Metal Products, an existing IntelliFinishing customer, has once again leveraged the power of IntelliFinishing to elevate overall operations and efficiency. (View the video of the JR Custom IntelliFinishing system.)
JR Custom is committed to competing and succeeding on quality, yet has found a way to ensure that quality is consistent while also promoting new efficiencies. Recently, the company added a Parker Ionics Prime Coat booth to its existing single-coat finishing system.
While JR Custom’s efficiency and throughput were already high as a result of their use of an IntelliFinishing system, installed in 2016, the company was seeking a way to efficiently offer a two-coat powder coating option on their single-coat system due to increasing customer demand for two-coat (prime and topcoat).
JR was already doing a two-coat process with their IntelliFinishing system when needed, but it required parts to move through the entire finishing system track twice, slowing throughput considerably.
The new addition needed to add this prime coat option in-line with the system and be installed with minimal downtime.
To address these needs, JR Custom chose to fit a new Parker Ionics Prime Coat booth into the company’s existing finishing system.
The booth was installed and integrated with the existing recipe software with an insignificant amount of downtime. The booth was positioned directly after the existing dry-off oven. For parts needing to receive a primer coat as part of their recipe, the parts are heated a little longer and hotter than normal in the dry-off oven, then immediately sent into the prime booth while hot. Pre-heating products before they are primed is a process called flocking.
Once in the booth, doors on the booth close behind and in front of the part, so the booth’s airflow system works properly – meaning the booth doesn’t pick up ambient heat from the nearby dry-off oven that could create an updraft that would tend to float powder up and out of the booth.
Integrating a door system to the existing track flow and software was extremely important to make the prime booth function properly.
After being primed, the product can then move along the remainder of the existing finishing track system for the top-coat application, final curing, cooling and unload.
Items that do not require a prime coat simply flow through the prime booth without stopping, as they would have on that section of track before adding the prime booth.
With the prime coat booth added to their existing system, JR Custom has one more service and recipe option for their IntelliFinishing recipe-driven automated finishing system.
“Now, I can offer my customers options on finish longevity,” said Jorge Martinez, Co-Owner. “A single-coat powder finish on my system routinely achieves about a 1,000 hours or more (depending on the powder and other options chosen) salt spray, while my two-coat process can achieve over 2,000 hours of salt spray test.”
“The best part is that we can simply toggle from a recipe that allows for one coat to a two-coat option without any other complications and with a system that maintains a high level of throughput capacity.”
JR Custom’s system flexibility allows for an extremely wide assortment of parts to be finished via the recipe system. They currently have hundreds of recipe options on their system, including options for shotblast or no shotblast, speed within the shotblast, number of times through the blast, pressure settings per stage in their wash, wash stage on/off options, unlimited time and temperature settings for the dry off and cure ovens, and many other possibilities.
Ultimately, the goal of JR’s system is for each type of part to be finished optimally based on its unique cure and finish requirements.
JR Custom’s IntelliFinishing System also saves money on utilities (up to 40%), because the conveyor rides above the ovens. There are no chains or carriers riding through the oven to soak up heat. There are also doors on the ovens to help keep the heat contained, as well as other energy-saving and insulating properties.
Thanks to its IntelliFinishing System, JR Custom Metal Products has a modular system with the ability to expand to meet changing process or throughput needs while also being cleaner, quieter, and much less expensive to operate than a comparable traditional automated system.
To learn more about how IntelliFinishing can help elevate your productivity, throughput, and efficiency without sacrificing quality and agility, contact us!
Click here to view the video of the JR Custom IntelliFinishing system in action and if you’d like to learn more about JR Custom Metal Fabrication, visit their website at www.jrcmp.com.
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.