Hand spraying is a skilled trade that is becoming obsolete due to advances in technology. Most notably, robotics have taken over a large portion of spray applications from their human counterparts in the liquid coatings industry.
As the technology becomes more and more popular, the need for a skilled human becomes less and less. However, regardless of advances in technology, there will still be a need for hand sprayers in liquid coating applications for a few different reasons.
The DECC Company is an almost exclusively rack-spray facility. During the coating process, components never touch…they are all sprayed and cured on their own hook. The only time they touch is during the packing process, and that is only if the customer requires a bulk pack.
Dip-Spin vs Rack-Spray
What this means is that compared to a dip-spin, bulk application process, parts coated in a rack-spray process will have a much more uniform and quality finish. The necessity of 100% sorting is eliminated. However, the most important distinguishing factor is that fallout from the coating process is almost nothing where dip-spin can yield upwards of 20% defective parts each run.
Although pricing for a bulk, dip-spin process may be enticing on paper, the total processing cost for certain part geometries that don’t lend themselves to a bulk application tends to be higher than a rack-spray price.
Below is a video highlighting the technology we employ at DECC. If you are having quality issues with a dip-spin application, be sure to contact us to see if we can help.
Last week we covered what the three most impactful changes to an organization would be when certifying to the new ISO 9001:2015 standard. This post is geared towards its application in automotive manufacturing.
Applying ISO 9001:2015 Standards to Automotive Manufacturing
The ISO standards are deliberately general so that they can be applied to businesses in every industry. However, that adds complexity when it comes to incorporating the ISO 9001:2015 standards in automotive manufacturing.
Thriving companies know that producing a quality product is the only reliable path to success. Most are well-versed in the International Organization for Standardization’s detailed program for incorporating quality throughout the business.
After three years of diligent work, experts around the world created a revised version of the ISO 9001:2008 requirements: ISO 9001:2015. Certified companies were permitted three years to upgrade their certificates, and by September 2018, all businesses will be operating at a new level of excellence.
A good amount of commercial food grade processing equipment comes “out of the box” with non-stick, FDA acceptable coatings applied to the appropriate machine mechanisms (learn why we say “FDA acceptable” and not “FDA approved” here).
As is with all new purchases, everything works great for a period of time. However, food ingredients can be surprisingly abrasive or acidic and coatings are not impermeable to wear, even the most robust ones.
Conversely, when the equipment does not come with a coating and sticking ingredients start impeding production for extended periods of time for cleaning, it is determined only after processing that one is needed.
In both instances, it is probably more cost effective to contact a local coating applicator to apply an FDA acceptable coating than it would be to contact the manufacturer for a replacement component or to have them locate an applicator.
However, it should be noted that there is no one cookie cutter FDA acceptable coating (no pun intended) that can solve every issue.
Ideally, today’s digital welding equipment can be fine-tuned to the point of producing almost zero spatter and weld engineers and technicians can lay a beautiful weld at the start of production with brand new equipment.
However, in a real world production setting, weld variables rarely stay tuned to a laboratory type setting. Weld fixtures become misaligned. Component tolerances vary over time. Weld equipment becomes worn. Weld variables change with every new trouble shooting attempt. Ultimately, these all contribute to the buildup of weld spatter.
There are multiple solutions to preventing mig weld spatter from building up and causing quality or productivity issues in your high volume welding environment.
When a manufacturing design engineer is developing a component, they are designing it to perform as intended in the field. Failure is not planned for because if there was a perceived threat of such during the design stage, it would be compensated for.
However, “failure” can constitute more than just a component malfunctioning or not performing in the field as intended…especially when a functional coating process is required.
For instance, would a part that requires 100% sorting after a coating operation – when that cost was not factored into the process – due to inadequate structural design be deemed a “failure” as well? We think it would (read our white paper regarding this specific topic).
Manufacturing design engineers should be sure to consider some of the following when in development of a component that will require a post coating application process:
I am currently an engineering intern seeking to earn my degree next spring. I started working for the DECC Company in the beginning of 2016 and the only prior experience I had in the coating industry was when I used a can of peelable spray paint on my rims to cover up some rust spots.
Producing quality product within a specified tolerance is a battle that every manufacturer, in every industry, fights every day.
Design engineers have the task of determining how tight of a tolerance should be allowed when developing a part and usually operate in the mind set of “the tighter the better.” In some cases, unnecessarily tight tolerances just drive up the cost of a component unnecessarily, but that is a debate for a different day.
Corrosion is one of the leading causes of component failure across all industries. In terms of functional coatings that offer corrosion protection, there are essentially two categories: sacrificial coatings and barrier coatings.
The type of corrosion being combated, as well as if there are additional performance criteria that the coating must achieve, will help determine which type of coating system you should use.