In case you missed this article in our July/August edition.
There have been so many game changing innovations in paint technology, preparation and ancillary equipment that sticking to the old ways makes no sense if you want to be profitable.
Before we address equipment and layout in the paint shop we asked the experts at the paint companies what they thought the three operational aspects most contributed to efficiency and they all said exactly the same – so this is gospel.
Clear goals, planning setting
Establishing clear, measurable objectives for quality, production rates, and feed back on customer satisfaction that every team member understands and strives to meet.
Planning daily operations, resource allocation and timelines. This minimises downtime and maximises productivity. Efficient planning includes contingency planning for unexpected delays.
Standard Operating Procedures
Implementing standardised procedures specific to the business and style of work. This should include process, housekeeping and safety. This ensures consistency in quality and reduces variability. It helps in maintaining high standards and facilitates easier training for new employees.
Process optimisation is regular reviewing and refining the processes to eliminate inefficiencies and bottlenecks in crucial areas. Using lean principles can help streamline operations, reduce waste, and improve efficiency.
Team Approach
Encouraging open communication and collaboration among team members fosters a sense of unity and collective responsibility. Regular meetings and feedback sessions can help in addressing issues promptly and share best practices.
- Investing in continuous training and professional development ensures that the team is skilled and up to date with the latest techniques and technologies. A well-trained team is more adept at problem solving and maintaining high standards of work.
- These three elements collectively ensure that a paint shop operates efficiently, delivering high quality results consistently while maintaining a motivated and cohesive team.
- Idea paint shop layout
- Ticking the box on the following will improve productivity.
- The paint shop should be designed with minimal vehicle movements and space for the correct turning radius to move a car/van.
- There should be enough space for a dedicated pre and post painted parts area.
- There should be a lot of thought about the kind of stands you put parts on – consult with your team.
- The paint shop should be on one level. If the shop has more than one level it should be on the higher level to save money on ducting.
- Skin protection, hand cleaning, first aid and chemical eye wash should be situated in the paint shop, not elsewhere.
- Have clear solutions for the disposal of rubbish such as tape and plastic – a clean shop is a happy shop.
- Sanding and consumables should be stored in a prominent, easy to reach position where you can easily check stock levels.
- Create an area where you can recycle your waste solvents instead of paying someone to take used solvent away.
- Size matters. With booths bigger isn’t always better and crowding a booth is counter productive. A crowded spray booth upsets airflow and means rework. Turbulence introduces dirt and dust. With low energy coatings it’s quicker and more energy efficient to use the booth twice than crowd it once.
- Using the latest technology
When we’re talking efficiencies its about getting more cars through the shop in an energy efficient manner to reduce your costs and boost your profits. In addition to the constant rise in gas and electricity prices your work providers could be expecting your to lower energy usage from next year.
- Use fast drying paints, primers, clear, fillers and premium sanding products. While they might be more expensive to buy they will save labour which is your biggest cost. However, make sure your team is trained to use them as they were designed to be used to derive maximum benefit.
- Invest in high quality LED lighting
- If you are in a cold winter area consider a heat exchanger in your booth as this offers big savings in the cold months.
- Use UV and infra red curing to dramatically reducing curing times and save energy.
- Automated paint mixing systems are a total game changer. The ROI is a no brainer for the majority of shops. PPG has Moonwalk, Sherwin Williams has Pronto. The other major paint companies will be introducing their versions very soon – make sure you put your hand up to be at the front of the queue.
While taking advantage of the latest in paint technology, paint mixing and colour matching will boost productivity and save on energy costs, don’t overlook simple efficiencies like using the best bumper stands and having a clean, dedicated area for painted parts.