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National Coil Coating Association

Nordyne, A Manufacturer Of Hvac Equipment, Reaps Major Benefits And Cost Savings With Prepainted Metal

CLEVELAND, OHIO — As a manufacturer using painted steel, aluminum, or other metals in the manufacturing process, the process of coil coating, or prepainting, can dramatically improve productivity, reduce processing costs, improve quality, reduce inventory and diminish environmental emission concerns—all at the same time.

 

Just ask Nordyne, Inc. a manufacturer of HVAC equipment. Quality has always been a top priority and this led to the switch from its internal electrostatic prepainting process to coil coating technology.

 

Before the change, Nordyne had a major concern with the coil coating technology as it related to products used outdoors, such as air conditioners. “We were unable to find a coated material that we felt could stand up to the outside elements, especially the salty air on the East and West Coasts,” reports Dodd Schimpf, plant manager. Nordyne has since made a 100% switch to coil coating on all twelve production lines and additional twelve subassembly areas. But, at the beginning, there were two major concerns the company faced during the change:

 

1) The occurrence of scratching parts during material handling and processing.

Solution: The company utilized dedicated storage containers or material that separated the parts. In the production area, dies were upgraded and polished so they did not scratch or mar the newly coated parts.

 

2) The need to create deep-draw parts without having the coated surfaces peel, crack or chip.

Solution: The key was teamwork between the processors, coaters and paint people who helped create the ideal formulation. They also reworked the dies and now produce the deep draw parts successfully 100% of the time.

 

In addition to overcoming these obstacles, Nordyne has had significant cost savings, quality and environmental improvements and most importantly, improved customer relationships and satisfaction.

 

1).Inventory: Nordyne has seen a 200% increase in raw material turns and reaped $1 million a year in inventory savings. The company has seen a drastic reduction of bottlenecks in the finishing process, and excessive inventory has been greatly eliminated.

 

2). Space: After selling their electrostatic system, the reduction of inventory freed up more space for manufacturing and more profitable uses.

 

3). Quality: The improved quality and reliability of the coil coating has resulted in an advantage over the competition and has brought more customers to the facility. The prepainted part has two coats of paint, tightly bonded to the metal as compared to a post-painted part, which generally has only one coat of paint. Besides an enhanced appearance, coil coating provides product durability and extended service life.

 

4). Environmental Compliance: Although Nordyne has always been clean from an emissions standpoint, they were still required by law to do a lot of reporting as a result of the postpaint system. . Professional coil coaters eliminate this problem. They have properly approved equipment which meets EPA environmental standards. Coil coating is one of the most environmentally friendly processes known for applying finishes to metals.

 

5). Customer Responsiveness: The coil coating process has allowed Nordyne to improve response time with their customers by increasing speed and flexibility and implementing Demand Flow Technology (DFT). DFT gets rid of the fabrication departments by integrating the work into production lines.

 

6). Productivity: As a result of precoating and DFT combined, Nordyne has seen a 400% improvement in the work flow process. Many delays in the plant are caused due to paint issues such as stoppage while parts are painted, dried, and cured before moving to the next stage of assembly. These bottlenecks can be eliminated with the use of prepainted metals.

 

Once the conversion process to coil coating is complete, your plant will run more efficiently, more effectively, and more economically. The ideal solution for a manufacturer looking to lower costs, improve productivity and run a tighter shop.

 

For more information about this study, or converting to prepainted metal, visit www.coilcoatinginstitute.org or call the NCCA at 216-241-7333.

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Contact

Leslie Schraff

216-241-7333

lschraff@thomasamc.com

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