| Description |
|
Robotic Painting of Plastic Parts |
| OEM, Model, Model Year |
|
General Motors, Chevrolet & Pontiac, 2002 |
| System Supplier |
|
Delphi Automotive |
| Molder/Processor, Contact and Phone |
|
Delphi Delco Electronics, Christopher LaBoskey, (956)618-7570 |
| Material Supplier |
|
GE Plastics |
| Generic resin type |
|
PC/ABS |
| Resin Trade Name |
|
Cycoloy |
| OEM Engineer, Title and Phone |
|
Dale L. Robertson, Plastic COE Engr. Mgr., (956)982-7049 |
| Nominated by, Company |
|
Christopher P. LaBoskey, Delphi Delco Electronics Systems |
| Address |
|
601 Joaquin Cavazos Road, Delnosa Plt. 6, Los Indios, Texas 78567 |
| Phone |
|
(956)618-7570 |
| Fax |
|
(956)618-7407 |
| Email |
|
Christopher.P.LaBoskey@delphiauto.com |
| Summary | | Lean manufacturing using robotic painting of plastic components for automotive audio systems, multiple colors. Improved painting yields, reduced emissions and scrap. Weight Savings: None. Cost Savings: $400,000/year savings in waste treatment Cost Avoidance: 50% greater throughput eliminating the need for additional equipment. $1,500,000. |
| Most Innovative Feature | | Lean manufacturing using robotic painting of plastic components for automotive audio systems, multiple colors. |
| Other Innovative Features | | Improved painting yields, reduced emissions and scrap. |
| Forming Process | | Conventional injection molding as well as multi-shot injection molding |
| First time process used? | | Yes, this is the first time multiple coats of paint applied robotically in a single system. |
| Previous Process Used | | Acrylic or polycarbonate molded pushbuttons, waterborne paint, laser etched graphics applied by reciprocating guns. Much higher scrap rates and paint waste. |
| Tooling Innovations | | Pushbuttons painted as a set with specific fixturing and programmable robotic spray guns, capable of painting up to 3 colors. |
| New Material Developments | | Waterborne paints, specifically matched to colors and formulated for laser etching |
| Weight Savings | | No appreciable weight savings. |
| Direct Cost Savings | | $400,000/year savings in waste treatment |
| Indirect Cost Savings | | 50% greater throughput eliminating the need for additional equipment. $1,500,000. |
| Direct Consumer Benefit | | No |
| Translates to other Vehicles? | | Unique application for manufacture of small plastic components. |
| Safety Benefits | | No direct safety benefits. |
| Environmental Benefits | | $400,000 per year savings in waste treatment costs. |
| Additional Info | | This has helped to significantly reduce in process inventories and buffer sizes in plant. |