Auto Manufacturer Reduces Defects, Saves US$300,000 with Automated Spray System
Auto Manufacturer Reduces Defects, Saves US$300,000 with Automated Spray System
Problem:
A manufacturer of automobiles needed to apply a misting of RO/DI water onto the floor pans of passenger cars and trucks to prevent dust from kicking up during the painting process. Applying the water manually with handheld spray bottles resulted in inconsistent coverage, sometimes causing dust to reach the exterior of the auto body. This not only inhibited paint from adhering to the surface but required transport to a body shop for repair.
The company required a spray solution that would use the same amount of water to consistently and evenly cover the floor pans and help reduce expensive rework.
Solution:
Spraying Systems Co. ran an on-site test with the AutoJet® Model 1550+ Modular Spray System to demonstrate its ability to control liquid flow and drop size. In partnership with a manufacturer of automotive painting equipment, four PulsaJet® AA10000JJAU air atomizing, electrically actuated spray nozzles were installed on robotic arms on either side of the production line. The arms entered the auto body through the windows to spray the floor pans. With a fine mist required to keep the floor dust at bay, Precision Spray Control (PSC) was used to generate low flow rates (1.3 to 2 gallons/hour [4.9 to 7.6 liters/hour]) and air and water velocities.
The AutoJet Modular Spray System was easily integrated into the OEM's equipment, providing complete, automated spray control of the nozzles and ensuring precise placement of the water with minimal waste.
Results:
The AutoJet® Model 1550+ Modular Spray System helped the auto manufacturer increase daily production rate, reduce dust-related defects by 90% and reassign four employees to other tasks. Paint, RO/DI water and compressed air consumption all were decreased as were costs related to transporting and reworking rejected auto bodies.
The efficiency of the entire system provided by the OEM, including the AutoJet system and PulsaJet® spray nozzles, led to a savings of US$300,000 for the company, allowing it to achieve a payback period of less than a year.
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