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Project Title: Optimizing Powder Coating Usage
• Team Name: Paint System Team• Location Information: Juarez, Mexico• Division: PDO – A Commercial Distribution
Products• Product Overview: Painted steel parts used for
electrical products
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Project BackgroundProducts Impacted:
Fusible Disconnect Power, Bus Plugs
Ventilated & Encapsulated Transformers
Powder Coating Process
Panel Boards, Switch Boards
Automatic Transfer Switches
Process Impacted:
1. Loading 2. Pre-Treatment3. Dry oven4. Paint Booth5. Cure Oven6. Unloading
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Project Background
• The current powder coat process is not precise due to a manually controlled system which results in high powder paint consumption and inconsistent paint thickness on steel parts.
Powder spray operation principleManual Gun Control
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How Does This Project Align With Your Plant’s Critical Success Factors?
Key StrategiesProduct Customization Responsiveness & Flexibility
• Process Standardization• Recipe Set Up Reduction
Lean Culture / Engagement• Shop Floor Team Member Participation• Promote and Execution of Employees’ Ideas• Increase Operator Knowledge of Process
Mesh Culture• Ergonomic Improvements• Establish Waste Reduction Awareness Key Metrics
23.89% Contribution Margin• Reduce Paint Consumption• Hazardous Waste Disposal Reduction
0.96% CONC• Reduce Rework Due Excess or Lack of
Paint
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What Are You Trying To Improve?
• Reduce paint thickness variation (Ranging from 2 to 6 mils prior to project start)
• Target to achieve cost out by applying corporate paint thickness standard of 1.5 mils minimum
• Achieve quality and consistency of paint application between production shifts and operators
• Address current equipment obsolescence reducing the risk of extended lost production time
Metal
Paint
Illustration of irregular paint thickness
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PlanWhat Approach Did You Use?
The new generation paint booths on market
Available EATON gun control equipment Time Line & Project Cost
PDC
A
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DOWhat Approach Did You Use?
• Transfer paint line controls available• Upgrade paint controls from 8 to 12 paint guns and
integrate into the existing paint booth
Automatic Gun: Automatic powder coating guns make powder application more consistent and cost effective
PDC
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Manual Gun: Manual application inconsistent, with production operators variation.
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DOWhat Approach Did You Use?
• Set up paint application recipes for high runner parts• Reducing the need for manual touch up improved the
ergonomic conditions
PDC
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Recipe: Parameters for flow, atomizing air and electrostatic settings
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CheckWhat Approach Did You Use?
• Daily paint thickness monitoring (PosiTector)• Data analysis and database storage• Continuous improvements to recipes
(adjustments based on collected data and test results)
• Adhesion, salt spray and impact tests
PosiTector: Electronic coating thickness gauges for ferrous metals
Database Storage: Software for downloading stored measurement results from the positector gage
PDC
A
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ActWhat Approach Did You Use?
iControl: Integrated automatic gun control system with closed-loop digital flow for consistent, repeatable coating performance. All gun parameters are user programmable.
Visual Aids: For operation of iControl
PDC
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Who Did You Involve?
Production:
Tool Crib:
Manufacturing:
Quality Control:
Sending Eaton Facility
Maintenance:Executives:Champion:
Finance:
Manufacturing: Define, Planning, TestingProduction: Execution, Follow UpQuality Control: Inspection, Follow Up Finance: Capital Appropriation, Asset TransferMaintenance: Equipment Transfer & Installation, TestingTool Crib: Quote & Supply MRO Items For System UpgradesSending Eaton Facility: Transfer Logistics; NegotiationsExecutives: Capital ApprovalChampion: Negotiation (Asset Transfer), Eliminate Road Blocks
Project Successful
Thank you All !!!
* Project Team Member
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• Reduced paint thickness variation (ranging from 1.5 to 3 mils) • Achieved cost out by reducing average paint thickness by 20% in
consequence waste disposal was reduced• Achieved consistency all shifts, all operators• Extend reliability of equipment• Sustainable results with expected improvements over time
What Were The Results Or Projected Results?
Average cost per square foot2011 was $0.1142012 YTD average is $0.092
Paint thickness variationNormal distribution before & after
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What Were The Results Or Projected Results?
PL100Q - ANSI 61 Gray:The standard powder paint used in paint system
Project ahead of schedule no saving forecasted for April
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Lessons Learned / Future Improvements
• Review at different Eaton facilities if there is available equipment to transfer before purchase or made big investment. special thanks to Eaton Mexicana for provide the required equipment.
• Production employees are experts at their processes, listening and working with them can achieve big improvements! It is important to create the desire to make the change successful; they understood the risk of do not change.
• Removing roadblocks was necessary to look for and present different alternatives for the same issue.
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Contact For Further Information?
• Diego Barrios – • Manufacturing Engineer
