Situation
- Problem: Inefficient powder utilization and frequent, unoptimized color changes were driving up material costs and reducing throughput.
- Goal: Increase powder transfer efficiency and streamline the scheduling of parts on the moving track.
- Context: The system utilized spray guns to coat charged parts on metal hangers across a continuous conveyor line.
Task
- Responsibility: Lead data collection, nozzle calibration, and the development of a digital scheduling solution.
- Constraints: Must work within part batch deadlines and provide an accessible interface for floor managers.
- Tech Stack: VBA (Excel-based tool), ultrasonic thickness gauges, and flow control sensors.
Action
- Data Analysis: Audited paint thickness across various part geometries and colors to identify areas of over-application.
- Process Tuning: Optimized spray nozzle outputs to ensure uniform coverage, reducing wasted powder and “orange peel” defects.
- Software Development: Built a custom VBA tool that allowed managers to input part batches and constraints.
- Optimization: Programmed the tool to minimize high-cost color changes and part-size transitions while meeting strict delivery timeframes.
Result
- Financial Impact: Netting $20,000+ in annual savings through reduced powder waste and improved labor efficiency.
- Consistency: Achieved high-uniformity coating standards, reducing rework by stabilizing paint thickness.