Automated paint spray systems: considerations and keys to successful implementation

The opportunities of today’s industrial automation allow for a lot more flexibility than in the past. As with any significant manufacturing change, the benefits and risks should be evaluated carefully prior to implementation.

Automation considerations

Although automation brings significant advantages, it should not be considered a good fit for every process. Prior to investing in paint automation, there are a few things to consider.
 

1. Return on investment (ROI)

Automation solutions are not cheap and should be considered a long-term investment. However, in small processes with low production quantities, the considerable purchasing cost of an automated paint spray system might not always be profitable. Before you open your wallet, you should compare the total purchasing cost with the expected proceeds to make sure you do not end up with a negative return on investment (ROI). 
 

2. Production flexibility

Machines are usually programmed to perform and repeat a specific series of actions over and over again. In a production environment where small production batches or rapid process changes are needed, automated solutions are less  flexible and versatile than an employee.
 

3. Machine emissions

Many automated machines are powered by an engine, which may cause gaseous or chemical emissions. This presents a health risk for employees, leading to a potential increase in absences. 
 

4. Additional costs

Take into account the possibility of several unpredictable costs that may exceed the actual savings due to the automation itself. These costs could include research and development costs of automating a process, preventive maintenance costs and the cost of training employees to operate automated machines.

 

Keys to successful paint spraying systems implementation

Having read all the considerations above, are you still convinced of the advantages of automation for your production environment? Perfect; so are we. But before you start implementing, we recommend the following steps.
 

1. Do your research

Before deciding to implement a finishing automation system, it’s essential to lay the groundwork. This involves researching and contacting multiple vendors to review your specific application and understanding the process accurately. 
 

2. Compare all current and expected production benefits

It is also vital to make accurate cost comparisons to your current production. Short- and long-term risks should be clearly identified and continually mitigated. All the benefits need to be carefully calculated in terms of cost, quality, delivery, workforce and safety. At the same time, the risks of not moving to automation need to be considered, such as increasing global competition, healthcare costs, liability and safety.
 

3. Develop a long-term automation strategy

Automation should be approached as a long-term strategic decision and a great opportunity to redesign your process and explore your entire value stream. For this, a comprehensive automation strategy is necessary. Deciding on the right time to start an automation project and selecting the right equipment is important for successful implementation. 
 

More information

Automation is the future of manufacturing. It has never been easier to automate, and it continues to get better and cheaper. Smart manufacturers are making the switch to automation now. For further information on how Graco can help you automate your finishing processes, contact us using the form below.