EXEL North America worked with Monarch Industries located in Winnipeg, Canada to reduce their Work-In-Process Time (WIP). Monarch’s goal was to be the best manufacturer of hydraulic cylinders.
Monarch Industries application consisted of automatic hydraulic cylinder finishing with an overhead monorail conveyor system. They were using manual Graco Electrostatic equipment and running three shifts with approximately 10 people per shift. Monarch was producing 2000 cylinders per day with varying batch sizes while each cylinder needed to be primed and top coated. The primer was a one color 2k epoxy, and the top coat was a 2k urethane in various colors.
EXEL North America was able to analyze their current situation and offer a more suitable solution that would offer a better Return on Investment. To optimize Monarch’s performance, create a long-term paint savings, and reduce the amount of labor, EXEL North America installed the following Kremlin Rexson equipment in Monarch’s facility:
- 04-120 and 04-220 Flowmax® circulation pumping systems
- AD-60 Paint Heaters
- 55 Gallon Agitator and cover lifts
- Two Cyclomix™ Experts for Primer (one manual and one auto)
- Two Cyclomix™ Experts for Top Coat (one manual and one automatic)
- Two Spraymium™ Primer Electrostatic spray guns for primer touch up
- Two Spraymium™ Top Coat Electrostatic spray guns for top coat touchup
- Primer automatic application system, RFV2400 dual axis reciprocator following system
with three PPH308’s
- Top Coat automatic application system with RFV2400 dual axis reciprocator following
system with three PPH308
One of the reasons this was a success was because the RFV2400 system allowed us to only spray on the apex of the cylinders, which provided a much higher Transfer Efficiency rate than previous systems. The system allows for rapid color change with fresh urethane at all times and we were able to control the process with an RFID control system.
EXEL North America was able to help Monarch Industries save on their painting costs. The paint costs went from $1.50 per average cylinder down to $1.00 per cylinder. With the new system in place, all cylinders are finished during one shift while the old system required three shifts with 10 people on each shift. In addition to paint costs savings, we were able to create a labor savings of approximately 20 people.