In our recent blog, "Why Quality Checks are Rising in Architectural Coil Coating," we noted that modern architecture involves:
- More colors than ever before
- Short runs
- High quality demands
- Long warranty periods
These requirements combine to increase the number of setups and quality checks that a coater must incorporate into his coil coating system to fulfill an order. In a competitive marketplace with razor-thin margins, this can place intense pressure on a coil coater by consuming valuable production time.
A Bad Mix
This combination of custom colors, short runs, and high quality and durability requirements create a “perfect storm” of problems for the coil coater. All of these are dependent on getting the film, finish, and adhesion properties right all at the same time. This leaves no room for error in the setup. But being a custom color – one that is probably a first-time run – there is likely no setup history to fall back on.
So what’s a coater to do?
The answer: test – test – test!
Testing is essential to ensure that the quality requirements are met, but at 20–30 minutes per test shot, these come at the expense of valuable runtime.
The Short Run/Custom Color Dilemma
When we say “short runs," we mean production lots that are often just a portion of a coil. This means a run duration of less than an hour in most cases – which translates to a color change every hour – or even more often. But, again, these custom color changes often require multiple trials, and with trials generally taking 20–30 minutes each, the end result is that setup and testing can end up taking more time than the actual run.
How can that possibly be cost effective?
The PCM - Metering Makes a Difference
The key to the success of the PCM is that its unique shape and position forms a gap across the face of the pickup roll that meters paint to the applicator roll which reduces edge-to-edge variations, providing a more even film build across the width of the strip. This is explained in greater detail in our webinar, “The Profile Correction Module – A New Approach to Coil Coating," if you would like to gain a better understanding.
For custom, first-time colors, this improved film control means getting the setup right faster. In fact, it is common to achieve the proper setup with one fewer trial!
A Problem Becomes an Advantage
As custom colors become more and more frequent for architectural projects, reducing trials is like putting time back in the bank. Imagine being able to save 20–30 minutes on every custom color job you run.
Taking on more of these jobs is no longer a frightening prospect – in fact, it becomes a chance to create an advantage over your competition.
While others are avoiding these short run custom color opportunities, you can aggressively pursue them – with confidence.
The Savings Keep Coming
Let’s assume that you have just two custom color jobs per week and you can reduce the trails required to run them by one trial each. This amounts to nearly an hour per week of extra production time. This is enough time to run another order – every week.
Even if you only run 50 weeks in a year, this is an opportunity to add an extra 50 jobs to your schedule every year – lucrative custom color jobs.
What would an extra 50 jobs mean to your business this year?
Download our free Coil World Article to learn more about the module and how it can help your business.