Lean MDF Powder Coating - Case Study

Lean Manufacturing - MDF Powder Coating

Lean Manufacturing, MDF Powder Coating, Case Study

“Increased productivity, reduced costs, winning business back from China. Now looking at 2nd line. I haven't even begun to advertise yet!”

Bells Powder Coating

https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

Still Skeptical About Lean Manufacturing?

If there are still sceptics out there about Lean Manufacturing, the please read this Lean MDF Powder Coating Case Study!

Some time ago we were contacted by Bells Powder Coating in Massachusetts. They had just gone through a Lean Manufacturing Program, and the savings allowed them to invest and expand. They chose to move into powder coating MDF, and bought a specialist Gas Catalytic Infrared oven from Vulcan Catalytic Systems (now Heraeus Vulcan). Gas Catalytic IR technology fits well with the principles of Lean Manufacturing as it helps to reduce some of the major sources of waste.

 Here are a few of the Before and After comment from Bells Powder Coating:

Before:

  • "Half a million $ in lost revenue"
  • "Another half million $ in work going offshore"
  • "We needed to get a handle on costs right away"
  • "Competition was intense"
  • "We wanted to move into hot new markets, like powder coated medium density fiberboard (MDF)"
  • "Return on investment was too long"
  • "At about $98,000 per year, our natural gas bill was a huge expense"


After:

  • "Increased productivity by 7%"
  • "Reduced costs by $70,000"
  • "Winning business back from China"
  • "Able to take a second look at launching the MDF product line"
  • "The Vulcan Catalytic (now Heraeus Vulcan) oven alone saved us $27,000 per year"
  • "15 companies interested in our powder coated MDF, through word of mouth alone"
  • "I haven't even begun to advertise yet!


Lean MDF Powder Coating

The added benefits of the MDF Powder Coating oven from Heraeus Vulcan, which is perfect for use in a Lean Manufacturing environment, means the benefits are multiplied, as they can make best use of the Lean advantages that an oven from Heraeus Vulcan can offer. Wait till we tell them about the advances in single coat technology for MDF. But I suspect they already know!

Heraeus Vulcan Leads the way

Heraeus Vulcan are the undisputed experts in MDF powder coating, having built the two largest, high production ovens in the world. Recent full production trials in Slovakia, ran faultlessly, with 0% defects. The trial only came to a halt when part production could not keep up with the powder coating line, and they ran out of parts to powder coat! Please contact us for further information.  


Heraeus acquires Vulcan Catalytic Systems Ltd.

Press release:
Hanau, June 10, 2014

Heraeus Noblelight has concluded and asset deal to acquire the business activities of Vulcan Catalytic Systems Ltd.
The acquisition of Vulcan Catalytic Systems expands the process heating portfolio from Heraeus Noblelight to include both gas and electric heating systems for industrial applications.
Mike Chapman, John Martin and key personnel will remain with the company, supporting existing customer base and developing new markets.
“Vulcan Catalytic and Heraeus share a common goal: to consistently exceed customer expectations,” Michael Chapman, President of Vulcan Catalytic Systems, pointed out. “Joining the Heraeus network will offer us numerous opportunities to introduce our products and expertise to new markets.”
Heraeus, the precious metals and technology Group headquartered in Hanau, Germany, is a global, private company with more than 160 years of tradition. We create high value solutions for our customers, strengthening their competitiveness for the long term Our fields of competence include precious metals, materials and technologies, sensors, biomaterials and medical products, quartz glass, and specialty light sources. In fiscal year 2013, Heraeus achieved product revenue of $5.46 billion and precious metals trading revenue of $17.55 billion. With some 12,500 employees in over 110 subsidiaries worldwide, Heraeus holds a leading position in its global markets.


Heraeus
Heraeus Nobelight, LLC.
1520 Broadmoor Blvd., Suite C P. O. Box 855
Buford, GA 30518
Tel: (678) 835-5764
Fax: (678) 835-5765
www.noblelight.net

Heraeus Vulcan
300 High Point Avenue
Portsmouth, RI 02871
Tel: (401) 683-2070
Fax: (401 683-6450
www.vulcan-mdf.com


Doughty Engineering Ltd. - Flexible Powder Coating System - Case Study

New Gas Catalytic Powder Coating Oven Improves Response Time

Powder Coating System Case Study

“Apart from the reduction in operating costs and the improvement in quality; the intangible benefits such as improved customer service and the ability to be more responsive will help us maintain existing and gain new customers. The new powder coating system has surpassed our expectations and made an immediate difference to our business"

Stephen Wright  - Director of Doughty Engineering Ltd

https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

New Powder Coating System Improves Response Time

Powder Coating System Case Study. Doughty Engineering is the world leader in the design and manufacture of rigging, suspension and lifting equipment for the film, TV and theatre industry. Prior to installing a new powder coating system, the company outsourced all their powder coating to two subcontractors. Whilst they were generally happy with service that was offered; typical turnaround time was anything from 2 days to a week. However, it became  clear to Doughty Engineering that over the last 5 years,  customers were becoming more demanding. They were holding less stock and so expected suppliers to hold large stocks and offer short lead times. Maintaining large stocks was not the answer, especially when there are 100's of products. However, the converse was not an option either. If a customer called for a part and it was not in stock, they would simply phone up another supplier. This created the risk of losing hard won business to competitors.

So the ability to become much more flexible and responsive became important. The answer was to bring 95% of their powder coating "in-house". Working with systems house Junair (Spraybooths) Ltd,  Gema UK and Caldan conveyors, the optimum system was designed and implemented. For the oven, Heraeus Vulcan Gas Catalytic IR technology was chosen due to its superior energy efficiency, small footprint, and improved finish quality over conventional convection technology.

What Happened Next?

The system has now been running faultlessly since February 2014.

Key improvements  are:

  • 10% operating cost saving
  • Increased throughput
  • Considerably reduced  lead times
  • Three hours not unusual
  • Rush jobs in custom colours carried out "While You Wait"
  • Improved quality
  • Increased capacity
  • Customer retention maintained
  • Production easier to manage