sign in sign up
<<
Home , Aerospace manufacturer

ProBatch Leadership Kit Automating the Kitting Process in the

Table of Contents

I. Situation Analysis

II. Application Basics

III. Graco Solution

IV. Return on Investment for Aerospace Customer

V. Application Benefits

VI. Ordering Information and Prices

VII. Other Potential Kitting Customers Automating the Kitting Process in the Aerospace Industry

I. Situation Analysis that with less than 25 gallons per day and use multiple colors generally use kitting in their operation. Even though kitting is relatively easy there is a tremendous associated to this method of mixing . Companies pay a premium to have the luxury of mixing kits instead of doing the mixing themselves.

Kits consist of two (2K) or three (3K) components that are purchased in separate cans and mixed together.

The benefit is that the proportion of each material is correct, which reduces errors in mix ratios, but the user lacks the flexibility in how much is mixed. For instance, if a touch up job requires one pint of paint, the combination of three components may yield a total of 1.25 gallons or the waste of one gallon of kitted paint.

The main components of kits consist of the following materials.

1. resin 2. catalyst 3. solvent

For the purpose of this application leadership kit, the aerospace industry will include aerospace manufacturers, aerospace feeders and military bases. The aerospace industry offers the greatest opportunities for the ProBatch system because it is an industry that requires many small amounts of a very expensive paint and is accustomed to using kits. It is not uncommon for an to waste up to 25% of their paint.

The aerospace industry has high quality standards and is closely watched by environmental agencies, therefore, the reduction of waste is on everyone’s mind. II. Application Basics The resin generally consists of a one gallon can of color, which can carry a price tag of $50 to as much as $300 per gallon. The catalyst generally consists of a one-pint can at a cost of $95 per gallon. The solvent generally consists of a one-quart can at a cost of $25 per gallon.

The kitting process generates a tremendous amount of unused paint, which also comes with a disposal cost for the cans. Not to mention the premium that is paid for the smaller containers of paint. a. Materials Used in the Aerospace Industry When calling on an aerospace it will be found that many different material suppliers will be supplying material. It is not uncommon to have as many as five different material suppliers. For instance, one company may supply the primer, another the paint for interiors, another for the landing gear and so on. A list of the main suppliers is below.

Supplier Industry Application Painted Part Typical Ratio Sterling Manufacturer, Feeder, Military, Primer, Interior, 2:1 Commercial (Urethane) exterior, engine, fuselage Deft Manufacturer (primarily ) Primer All 2:1:4.5 (Water Borne) U.S. Paint Manufacturer, Feeder, Military, Topcoat Interior, 3 to 4:1 Commercial Airlines (Urethane exterior, and epoxy) engine, fuselage, edges Sherwin Manufacturer, Feeder, Military, Topcoat Interior, 3 to 4:1 Williams Commercial Airlines (Urethane) exterior, engine, fuselage Dexter Manufacturer, Feeder, Military, Primer, Landing Gear 3:1:1 Commercial Airlines Topcoat or 3 to 4:1 (Urethane) Desoto Manufacturer, Feeder, Military, Anti-stat Exterior 2 to 3:1 Commercial Airlines

It is recommended that material suppliers be contacted before going into a potential aerospace customer in order to determine what paint is being used and if any material changes are foreseen.

Many companies still use military specification. The common military spec that is used is mil spec 1011. Another interesting note is that the Sherwin Williams’ aerospace division does not sell to the military. Only the Chemical and Coatings division sells to the military. The aerospace division has no paint that meets mil spec 1011. b. Customer Type Both the aerospace feeder and manufacturer are similar in their painting requirements and material used. The main difference is that the aerospace feeder will have many more colors in stock due to the fact that they supply multiple manufacturers. Some feeder plants may use up to 60 different colors in one day.

The aerospace manufacturer can use up to 30 gallons of primer each day and 30 gallons of topcoat per day. The primers are generally 2K and the topcoats can be 2K, but 3K are more common. In humid environments solvent is used to increase the potlife time.

Military bases have the same needs as commercial airlines, where touchup and repainting is required. The important thing to know about selling to the military is that it is essential to speak their language. For instance, you do not want to call on the purchasing manager--in the military this person is called the procurement officer. c. The Kitting Environment A typical manufacturer may run two shifts and have 5 to 15 painters per paint kitchen. There generally will be a paint crib attendant who will mix the batches for primer and color. These painters will get batches anywhere from 4 oz. to 5 gallons, but a typical batch will be a pint or quart. The problem is that when hand mixing is done by the paint crib attendant the batch sizes are generally larger and paint is often wasted due to expired pot life from too much material being mixed that amounts to at least 10% of the batches. Also, there is a delay when the production shift starts and the painters are waiting for the kits to be made. It is common to see painters waiting in line for 15 to 30 minutes. The result is lost production time and unwanted socializing. A painter will come to the paint kitchen 4 to 5 times per night.

Another problem that was discovered is that with so many different material suppliers, there are also many different catalysts. It was found that when painters were making their own batches from kits, they often used the wrong catalyst, because they did not understand that there could be a different catalyst for each paint. When bad parts need to be reworked it is a tremendous cost to the manufacturer in terms of lost production.

Wasted paint is expensive. Not only is the cost of the paint being incurred at a minimum of $50 per gallon, but there is also a cost associated to disposing of this unused paint that can amount to as much as $1,500 per 55 gallon drum.

Average Average Daily Average Weekly Bad Paint Type Paint Cost Paint Waste Mixes Primer- Urethane $50 to $60/gal. 10% 5% Primer – Deft $100/gal. 25% 5% to 10% Top Coat $50 to $300/gal. 10% 5% PTFE $200/gal. 10% 5%

Empty paint cans from kitting also is considered and must be disposed of appropriately. An aerospace company is required to wash out the cans, dry it and contain it in hazardous material containers, often 55-gallon drums. These drums are then shipped to hazardous locations at a hefty fee, along with a separate drum that contains the solvent used to wash out the cans. One manufacturer stated that they would have an eight month ROI on the ProBatch just from the cost of eliminating the labor and cost of washing and disposing of the cans. Every plant is reviewing their environmental emissions. The current method of recording solvent usage is by the amount of solvent that is left in inventory at the end of the month. The more wasted paint, the more solvent that needs to be reported.

III. Graco Solution

The solution to this wasteful process is to use the ProBatch, electronic batch dispensing system. This weight-based product is a cost-effective solution to the kitting process. ProBatch uses a scale to measure the exact amount of material required to make the perfect mixture every time. ProBatch offers the range of dispenses from as low as 4 oz. to 5 gallons.

The system can handle up to 99 fluids, 6 maximum for automatic dispenses and 93 for manual adds. A total of 250 recipes can be programmed into the ProBatch through screen inputs or through PrecisionView AMR 2.0.

The typical return on investment (ROI) for the ProBatch will range from 1 to 10 months.

The benefits of the ProBatch in the aerospace industry is that it: 1. Improves Paint Quality 2. Reduces the Amount of Waste 3. Improves Production by Reducing Painter’s Down Time 4. Eliminates the use of Can Disposal 5. Reduces the Overall Disposal Cost 6. Frees Up Paint Crib/Kitchen Staff to on Other Projects/Tasks 7. Keeps the Material Fresh 8. Reduce VOC

When the ProBatch was introduced at Raytheon Company in Witchta, KS, they were having bad batches on 10% of their hand mixed kits. When they installed the ProBatch and initially only dispensed the primer, they virtually eliminated their bad batches. The top coats that were not switched were still experiencing the 10% failure rate. How to Reach the Customer To find the right person at an aerospace company can be tricky, but the best person to contact is as follows.

Company Best First Contact Aerospace Manufacturers Environmental Person

Aerospace Feeders President Paint Foreman/Supervisor

Commercial Airlines Research and Development Environmental Person

Military Procurement Officer, Corrosion Officers (Corrosion Control Department) or environmental engineers

Focus on primer and only major colors, the ProBatch is not a tinting machine.

IV. Return on Investment for Aerospace Customer

The ProBatch system is an ROI sale. Most companies look for a return on their investment within one year, which in most cases is obtainable even with the feed system. The following ROI model will help you in calculating the ROI for the customer. There are some additional intangible selling points that also can be mentioned. They include the waste disposal cost of liquid at up to $1,500 per 55 gallon drum, lost production time due to painters waiting for their paint at shift startup and breaks, and the reduced cost from eliminating the part rework from bad batches. The following ROI model looks at the savings from waste reduction associated with throwing away unwanted paint when kits are used.

ROI Model for Replacing Kits in the Aerospace Industry: n 6 Valve ProBatch: $15,800 n Cost of Feed System: $7,500 n Paint Used/Day: 10 Gallons n Resin Price/Gallon: $90 n Material Waste: 15% n Total Paint Usage/Year: $216,000 n Total Waste/Year: $32,400

ROI: 8.6 months with feed system 5.8 months without feed system V. Application Benefits

Kitting Problem ProBatch Benefit Mixing more paint than is required Only mix the material that is required. and discarding up to 25% of the batch. Disposing of waste paint. Reduction of wasted paint reduces the need for paint disposal. Labor intensive. Allows for fewer paint crib attendants. Cleaning and disposing of empty When purchasing in larger quantities cans that are considered hazardous and using fewer cans, the result is a waste. reduction of clean up time and waste removal. Increased cost of material due to Kits generally are purchased in one- smaller quantity purchases. gallon cans or increments. By using the ProBatch, companies are able to purchase material in larger quantities. Risk of using incorrect catalyst when Many times bad batches made from multiple catalysts are required. kits are a result of the wrong catalyst being used. The ProBatch eliminates this problem. Lost production time from painters The ProBatch system significantly waiting for batches from kits at start reduces the time required to make a of shift and breaks. batch and will increase the production of the painters. Lost production time due to The ProBatch dispenses at a rate of socializing at paint crib while waiting roughly one gallon per minute and will for paint. eliminate the down time that painters have waiting for their kits to be made at the beginning of the shift. More concern for pot life with larger The ability to mix what you need when batches. you need it greatly reduces the need to rush jobs before the pot life of the material expires. Difficult to adapt to humidity changes. Recipes can be created for various weather conditions. Production recording is cumbersome. ProBatch records all material usage and with PrecisionView AMR 2.0 the data can be easily reported. Training. Training painters on which paint and catalyst to use is time consuming, where anybody can learn how to use the ProBatch in 5 to 10 minutes. VI. Ordering Information and Prices

U.S. Prices Package Part numbers List Price Net Price 3 Valve System 244440 $14,000 $9,800 6 Valve System 244441 $15,800 $11,060

Canadian Prices Package Part numbers List Price Net Price 3 Valve System 244440 $20,875 $14,615 6 Valve System 244441 $23,550 $16,485

VII. Other Potential Kitting Customers

Kitting Customers Environment Automotive Feeders · Solvent blending · 2nd tier feeder (< 20 gal/day) · Manual spray Recreational · Touch-up SMC (Sheet Molded · Touch-up Components) Bus/Truck/Trailer · Touch-up Manufacturers Manufacturers · Acid catalyzed material – direct coating (top coat) · High ratios (up to 50:1 ratio) · Use material supplier as a reference · MEKP (high end furniture, musical instruments, boats) Signs · Highway signs · Billboard frames · Company signs/exhibits Caskets · Metal caskets · 2K materials · Shading Software Solutions

ABOUT GRACO ™ PROVEN QUALITY. LEADING . PROBATCH Founded in 1926, Graco is a world leader in fluid handling systems and components. Graco products move, measure, control, dispense and apply a wide range of fluids and viscous materials used in Printer Personal Computer PrecisionMix II PrecisionMix II 3K lubrication, commercial and industrial settings. Electronic Batch Dispense System accurately dispenses ProBatch Informer The company’s success is based on its unwavering commitment to technical excellence, world-class multiple-color, plural component paints

TM and unparalleled customer . Working closely with qualified distributors, Graco PrecisionView AMR 2.0 software option allows EasyKey 123

456

789 offers systems, products and technology which set the quality standard in a wide range of fluid handling the user to program recipes from a desktop computer .0 solutions. Graco provides equipment for spray finishing, protective coating, paint circulation, lubrication, and link to other Graco products to produce and dispensing sealants and , along with power application equipment for the contractor consolidated reports. AMR 2.0 also easily integrates industry. Graco’s ongoing investment in fluid and control will continue to provide production data with other plant databases, and innovative solutions to a diverse global market. is compatible with ODBC and SQL-compliant ® applications, including Microsoft Excel, Word, GRACO HEADQUARTERS Access and others.

PROBATCH AMERICAS EUROPE ASIA PACIFIC

MINNESOTA BELGIUM KOREA Worldwide Headquarters European Headquarters Graco K.K. Graco Korea Inc. Graco Inc. Graco N.V. 1-27-12 Hayabuchi Choheung Bldg, 4th Floor 88-11th Avenue N.E. Industrieterrein - Oude Bunders Tsuzuki-ku #1599, Gwanyang-Dong, Dongan-Ku Minneapolis, MN 55413 Slakweidestraat 31 Yokohama City, Japan 2240025 Anyang-Si, Gyunggi-Do, Korea 3630 Maasmechelen, Belgium Tel 81 45 593 7300 431-060 Return-on-Investment MAILING ADDRESS Tel 32 89 770 700 Fax 81 45 593 7301 Tel 82 31 476 9400 P.O. Box 1441 Fax 32 89 770 777 Fax 82 31 476 9801 Use this exclusive Return-on-Investment analysis tool to see exactly how much your paint line currently Minneapolis, MN 55440-1441 costs you, where there is waste, and best of all, how quickly a Graco ProBatch pays for itself. Tel 612 623-6000 Graco Ltd. Fax 612 623-6777 Representative Office Room 118 1st Floor No. 2 Xin Yuan Typical Scenario Calculate Your Savings No. 509 Cao Bao Shanghai, P.R.China 200233 Paint price per gallon $60 Tel 86 21 649 50088 (Typical $60/gal) Fax 86 21 649 50077 X X Gallons used per day 15 gal (Typical 15 gal [56.78 L]/day) X X days per year 250 days = = $225,000 Total paint cost per year Call today for product information or to request a demonstration. X X 1. 877.84 G R ACO (1-877-844-7226) or visit us at www.graco.com. 15% Total waste per year All written and visual data contained in this document are based on the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. (Typical 15% per year) = = Graco Inc. is registered to I.S. EN ISO 9001 //Service North America $33,750 Annual Paint Savings Industrial Customer Service 800-328-0211 FAX 877-340-6427 *Actual performance may vary depending upon materials and process. Industrial Product Information/Demonstration 1-877-84GRACO (1-877-844-7226) FAX 612-378-3597 Find out how to save today!

Graco ProBatch...setting new standards in electronic batch metering excellence! GRACO INC. FINISHING P.O. Box 1441 Call 1-877-84GRACO (1-877-844-7226) for the Graco trained and authorized Minneapolis, MN 55440-1441 distributor nearest you. PROVEN QUALITY. LEADING TECHNOLOGY. ©2001, 2004 Graco Inc. 300549 Rev. B 9/04 Printed in U.S.A. All other brand names or marks are used for identification purposes and are trademarks of their respective owners. ProBatch ... Eliminates problems associated with hand mixing! Four easy steps to set up and operate the ProBatch system.

Easy recipe setup 1

Finally there’s an inexpensive alternative to ™ FloSync Controller Recipe#: 12

the expensive kitting of small batches! Tracks and adjusts to fluid Step Fluid# Parts (by weight) 1 1 1 viscosity for faster and more 2 2 2 ™ 3 0 0 ProBatch accurate dispenses. 4 0 0 5 0 0 EasyKey™ Pad 6 0 0 offers an EASY, ACCU R ATE batch If Fluid#=0, Parts=pause in minutes/10 Provides user-friendly menu System Scale Fluids Recipes system that will R EDUCE WASTE and navigation and data input. Compatible Fluids SAVE MON EY. ProBatch is specifically • Solvent-Based Paints/Catalysts PART NO. 244441 PART Easy to select dispense recipe and amount designed for the cost-conscious individual 2 • Solvents who uses many colors in low volume. • Lacquers • Primers Versatile • Waterborne Paints/Catalysts Recipe: 12 Part No. 244441 Adjustable dispense Floor model with point allows Amount: 10.0 lbs Features 45º tilt screen dispensing from a pint-size container ID# 1111

• Program up to 250 recipes • Compatible with Graco’s to up to a 5 gallon Run Last Total All Totals Alarms PrecisionView™ AMR 2.0 software • 99-fluid capacity (18.93 liter) Easy Installation • Floor model has 45° tilt screen container. • Dispenses batches as small as 4 ounces for easy viewing Package complete – just add feed system, • Dispenses one to six dedicated fluids Monitor Dispense • Sliding scale for manual-add current, air and electricity. 3 • Centralized dispense of fluids into a cup gun • Adjustable dispense positions reduce splash Easy to Maintain or 5-gallon [18.93 liter] container Pull-out drawer feature allows • Revolutionary cascading pressure system easy cleaning of internal ID#: 1111 • Intrinsically safe Recipe: 12 for fast, accurate dispenses components. • Manual-Add features Step: 1 Fluid#: 3 Step Target: 1.00 Batch Target 17.00 Step Actual: .50 Batch Actual: .50

Key Applications lbs Accurate Dispensing High-resolution, weight-based Finishing Touch Up General 50 lb (22.68 kg) scale for accurate dispensing. Aerospace Automotive Any 2 or 3-component Batch total summary for ratio assurance 4 paint application Automotive Feeding Farm & Industrial Commercial Airlines Truck & Bus Any application with Furniture Recreational Vehicles Dispense Complete multiple colors using Recipe: 12 Batch Target: 17.00 ID#: 1111 Batch Actual: 17.00 Military less than 25 gallons Step: 1 2 3 4 5 6

(94.63 liters) per day Fluid#: 3 42 27 0 2 6 Trailers Target: 1.0 3.0 6.0 3.0 3.0 4.0 Actual: 1.0 3.0 5.99 3.0 3.01 4.0 Signs % 0 0 -.16 0 +.33 0

Remove container to dispense again. lbs. 325016B SS ProBatch 6/7/05 9:25 AM Page 1

Technical Specifications

Power Requirements Electrical ...... 85-265 VAC .25 amp maximum 50 or 60 Hz Pneumatic ...... 85-120 psi @ 1/4 cfm maximum filtered to 10 micron Material Requirements Number of Fluids (Total of 99 fluids): Automatic Dispense: ...... 6 fluids maximum Manual Dispense: ...... 93 fluids Specific Gravity ...... 5 to 2.0 Viscosity ...... 5 to 2000 cps Dispense Ranges Amount ...... 4 oz (118 grams) to 5 gallons (18.94 liters) Tolerance ...... ± 1% to 3% Flow Rates ...... 1/8 to 2 gpm (.47 to 7.5 lpm) Scale Data Capacity ...... 50 lbs (22.7 k) or 5 gallons (20 liters) Deck Size ...... 12 in. (30.5 cm) x 12 in. (30.5 cm) Container Sizes Height maximum ...... 18 in. (45.7 cm) Diameter maximum ...... 12 in. (30.5 cm) Diameter minimum ...... 2.5 in. (6.35 cm) for multi-valve dispenses Recipes Quantity ...... 250 Pause times ...... 1 to 99 minutes Pause steps ...... 3 maximum System Weight ...... 125 lbs (56.7 kg) Height (fully extended) ...... 44.5 in. (113 cm) Width ...... 22.2 in. (56.4 cm) Depth ...... 26.1 in. (66.3 cm) Fluid working pressure ...... 250 psi (17.3 bar) Porting Fluid ...... 3/8 in. (.95 cm) npsm(f) Pneumatic ...... 1/4 in. (.635 cm) npt Fluid Valves 3 valve system ...... (1) 1/8 in. (.32 cm), (2) 1/4 in. (.635 cm) 6 valve system ...... (2) 1/8 in. (.32 cm), (4) 1/4 in. (.635 cm) Approvals ETLul, ETLc, ETLis

EasyKeyTM 123

456

789

.0

ProBatch Installation Configuration

Bulk Tank

©2001 Graco Inc. Form No. 325016 Rev. A 3/01 Printed in the U.S.A. All data in this document is based on the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. 325016B SS ProBatch 6/7/05 9:25 AM Page 2

ProBatch™ Product Information

Ordering Information 1. Select a ProBatch Unit 244440 ProBatch 3-Fluid Three valves for up to three fluids One 1/8 in. valve and two 1/4 in. valves 244441 ProBatch 6-Fluid Six valves for up to six fluids PrecisionView AMR 2.0 Two 1/8 in. valves and four 1/4 in. valves 2. Distributor-Supplied Feed System Typical Feed Packages May Include: 5-15 gal (18.9-56.8 l) pressure pots Husky Diaphragm Pump Piston Pump 3. Accessories Control Box Adapter PrecisionView AMR 2.0 197502 243377 Single station license 243378 Up to 5 station license 243379 Up to 31 station license 244534 ProBatch Barrier Kit with AMR 2.0 For use in hazardous areas 115769 500 ft. (152 m) Beldon 9841 Network Cable 115770 1,000 ft. (304 m) Beldon 9841 Network Cable 116542 25 lb. (11.3 kg) Calibration Weight Calibration Weight Official weight for calibration of the scale 116542 197502 Control Box Adapter Allows the operator to view the screen at a 45º angle 239873 Printer Kit Includes 113774 printer and 192491 25 ft (7.6 m) power cable 514037 Printer Paper 244509 Printer Barrier Kit For use when ProBatch is in a hazardous area 197902 Paint Shield Membrane This clear membrane comes in a pack of 10 and protects the screen from fluids 4. Upgrade Kits 244382 1/8 in. (3 mm) Valve Needle and Nozzle 244383 1/4 in. (6.3 mm) Valve Needle and Nozzle 244384 Stainless Steel Valve Needle and Nozzle Printer 244792 Dispense Valve Assembly Kit/Less Valves 113774 - Regulator, mounting hardware, tubing, fittings 5. Repair Kit 244385 Needle Nozzle Kit Accessory: 1/8 in. (3 mm) 244386 Needle Nozzle Kit Accessory: 1/4 in. (6.3 mm) 244387 Needle Nozzle Kit Accessory: Stainless Steel Note: For fluids with viscosity greater than 2,000 cps, the ProBatch regulators can be bypassed and feed systems connected directly to the valves. 325016B SS ProBatch 6/7/05 9:25 AM Page 3

Plural Component Product Selector Guide

# of Colors Gal (L)/Day Description Product 1 2-3 4+ <25(95) >25(95) ProMix™ Easy X X X The ProMix Easy entry-level sprayer replaces manual premixing of plural component materials.

ProMix™ II X X X X X The ProMix II with Gun Flush Box eliminates solvent and paint waste from purging manual applications.

PrecisionMix® II X X X The PrecisionMix II electronic proportioner provides on-demand ratio proportioning and control.

PrecisionMix II 3K X X X The PrecisionMix II 3K electronic proportioner replaces manual premixing of solvent in plural component materials.

ProBatch™ X X X The ProBatch electronic batch dispense system dispenses multiple batches per day with excellent ratio assurance.

ProMix Easy ProBatch 325016B SS ProBatch 6/7/05 9:25 AM Page 4

Plural Component Product Performance Guide

ProBatch ProMix Easy ProMix II PrecisionMix II PrecisionMix II 3K Ratio Assurance 1% 1-5% 1% 1% 1%

Ratio Range 1:99 1:1 - 3:1 1:1 - 30:1 0.6:1 - 30:1 0.6:1:0.6 - 20:1:10

Flow Rate (cc/min) 200-4000 3800 3800 3800 2000

Maximum Pressure 250 psi 400 psi 4000 psi 3000 3000 (17.2 bar) (27 bar) (276 bar) (207 bar) (207 bar)

Diagnostics (online) X X X X

Patented Mixing Technology X X X X

Intrinsic Safe (option) X X X X X

Gun Flush Box (option) X X X

Pot Life Alarms X X X X

Automatic Flush X X X

Printer (option) X X X X

Network (option) X X X

Recipe Control X X X x

Automatic Color Change (option) X X

Flow Control (option) X X

Automatic Solvent Reduction X

PrecisionMix II ProMix II & PrecisionMix II 3K Raytheon QE 8/16/01 10:16 AM Page 1

PROBATCH™ ELIMINATES BOTTLENECK AT RAYTHEON

Raytheon Aircraft Company uses the Graco ProBatch™ to dispense a two-component epoxy primer into pint, quart and gallon containers, reducing waste and downtime.

painters waiting for material at one time,” says J.D. Mavity, Section Manager of the the Paint/Process Department. “It wasn’t a very efficient process. Furthermore, if the CM was rushing to keep up with a line of painters all needing material, the chance of inaccurately hand-mixing the two-component paint increased. If the material was FINISHING off-ratio, it could result in a poor cure rate or in extreme cases, rework.” “In addition to being time- In an effort to reduce a the painters started work to consuming and inaccurate, the APPLICATIONbottleneck in an area of their hand-mix the materials in 5- process was messy and resulted CUSTOMER Wichita facility where aircraft gallon batches. He would then in a high amount of wasted Raytheon Aircraft Co., parts and components are ladle the paint into pint, quart paint,” adds Larry Keefer, Wichita, KS painted, Raytheon Aircraft and gallon containers so when Process Engineer. “We needed a Company - a world leader in the painters arrived, they could more productive, cost efficient APPLICATION business and special mission get right to work. As the day system.” Painting aircraft parts aircraft - installed a batch progressed, he would hand-mix Raytheon installed a Graco & components dispense system to accurately additional batches and ladle ProBatch™ Batch Dispense dispense a two-component these out to the painters as System. The electronic system PROBLEM primer. Almost immediately, they needed more material. provides a cost effective and Hand-mixing caused the new system significantly Typically, the CM filled environmentally compliant a bottleneck and reduced the bottleneck, between 120 – 140 requests solution for dispensing batches excessive waste improved quality and reduced each shift. of plural component materials. waste. The primer and topcoat The system allows Raytheon’s SOLUTION Prior to installing the were metered in these small painters to quickly dispense Graco ProBatch™ batch dispense system, the amounts because the material variable batch sizes as small as Batch Dispense two-component primer and has a pot life. On hot four ounces to meet changing System plural component topcoats days, the metered material can job requirements with high on- were hand-mixed by the Paint cure within 90 minutes. The ratio assurance. The painter RESULTS Department’s crib managers material that isn’t sprayed simply places his container on Bottleneck eliminated (CM). To keep pace with within this time period has to the scale, enters the amount of and waste reduced production, the first shift CM be thrown away. material he needs and presses a significantly had to arrive an hour before “There could be 7 – 8 button to start the dispense Raytheon QE 8/16/01 10:17 AM Page 2

process. It’s simple to operate. “When we get a new painter, I take him over to the system and show him how it works,” says second shift CM Macon McMillan Jr. “In five minutes he knows how it operates and he can dispense his own material.” The easy-to-use computer-driven system links pre-programmed recipes with weight-based metering to dispense base and catalyst from 10- gallon pressure pots into a single batch container. The controller can store the parameters for up to 99 fluids and 250 recipes. When Raytheon received the ProBatch system, they decided to use it to batch their two-component epoxy primer. “We spray over 225,000 parts in this area every year and every part is Painters use Graco’s Delta™ spray guns to apply the primer and topcoat colors. They use the ProBatch to accurately dispense the plural component primer which the painters spray on all primed. This material accounts for over parts and components. 50 percent of our paint usage. It was just logical to see what effect it would have on reducing this bottleneck.” Now painters can step up to the The ProBatch system also reduced waste.” ProBatch and dispense their own waste. “During the day, I would get rid The CMs from both shifts agree primer, in the amounts they need. It’s of mixed material that was starting to that the ProBatch has made their job fast, clean, and accurate. cure,” says McMillan. “At the end of my easier. “It’s not as hectic and I don’t “It’s so convenient,” says Mavity. shift I had to get rid of the unused have a line of painters waiting for me “The painter dispenses his primer and primer and paint in my mixing pails. to mix up a batch of paint for them gets right back to work. There’s no Typically, I threw out 3-5 gallons of anymore,” says McMillan. “It allows waiting in line. No holdups. We’ve mixed primer and paint every night. me to do a better job on my other increased production by about 10%. Since the ProBatch was installed, we’ve chores.” • And since we began using the system virtually eliminated primer waste we haven’t had a single off-ratio because the two-component materials incident.” aren’t mixed until the painter dispenses the base and catalyst into a container placed beneath the system’s dispense valves.” The ProBatch has worked so well that Mavity hope to install a second ProBatch to meter their two primary topcoat colors — a glossy white, high solids epoxy and a black high solids urethane. Each material uses a different catalyst so they would need a ProBatch that could dispense 4 different materials, plus another dispense valve for solvent. This isn’t a problem because the ProBatch system is available with either three or six dispense valves. “The primer and two primary topcoat colors For additional product information or the account for 85 percent of the material name of a local authorized Graco used in this area,” says Mavity. “If we distributor, call toll free 877-844-7226 in had a second system, we’d completely the U.S.A. In Europe: (32) 89 770 700 eliminate our paint room bottleneck, as ©2001 Graco Inc. Form 320434A 8/01 well as increase quality and reduce Printed in the USA