The challenge
A manufacturer in the metalworking sector approached us to improve the quality of its powder coating while controlling its production costs. Against a backdrop of sustained energy cost increases since 2022 and stricter carbon requirements, it needed a partner capable of guaranteeing:
- Consistent powder coating quality,
- Short lead times (maximum one week),
- Continuous improvement of its process to secure its industrial and economic performance
economic performance.
Our solution
Implementation of a continuous Lean Kaizen approach at our ACS industrial painting and powder coating site. A dynamic of continuous improvement, based on the cycle of observe → test → measure → adjust. This approach allows us to guide our actions based on real data, observing the energy impact of our adjustments on a daily basis.
Installation of IoT sensors
Installation of connected sensors on burners to monitor energy consumption and operating profiles in real time.
Optimization of heating times
Settings adapted to the type of parts and volumes, reducing unnecessary processing times and improving process accuracy.
Partial switch to low-temperature powders
Introduction of specific powders to reduce consumption while ensuring adhesion.
Investment in new equipment
Installation of a high-efficiency heat exchanger, radiant panels to accelerate powder gelation, air curtains to reduce heat loss, and an
oil separator to ensure the degreasing bath remains clean at all times.
Results obtained
More stable powder coating quality
- Consistent baking profiles and uniform gelation ensure greater consistency in the final result, with enhanced adhesion and a reliable finish on all treated parts.
Controlled industrial costs
- Reduced energy consumption and stabilization of production parameters have helped to contain costs despite volatile energy prices.
Improved carbon performance
- The reduction in energy consumption has led to a direct reduction in emissions linked to the powder coating process.
Energy management
- Thanks to IoT sensors and optimizations, ACS has reduced its gas consumption by 15% while increasing its revenue by 15%.
Increased flexibility
- Dynamic settings, guided by IoT data, now make it easier to absorb variations in volume and part type (small series, large series, heavy or complex parts).
Conclusion
By adopting a continuous Lean Kaizen approach and investing in concrete technological solutions, we were able to address our client’s issue. This dynamic not only benefits current clients, but also serves as a real lever for competitiveness and reliability for all of ACS’s current and future partners.
