ChemOPS PreTreatment

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ChemOPSPre-Treatment Paint Line Manager

Automatic Pre-Treatment Washer Controller
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Business Objective
Overview
Paint Department Goal Consistently produce a
paint finish that achieves customer quality at
the lowest cost
Quick Facts
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Business Problems
Overview
Examples of defective paint coatings
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Process Control Strategic Vision
Vision
Full system control Full SPC reporting and trend
analysis Remote and wireless monitoring Automated
alerts and problem diagnosis
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ChemOPS Pre-Treatment Washer Controller
Overview
ChemOPS automatically monitors, controls and
adjusts chemical concentrations to ensure
effective product cleaning coating conversion

• Benefits
• Achieve customer quality expectations
• Decrease labor and costs
• Quick ROI payback (3-12 months)
• Supports Statistical Process Control (SPC)
• Six Sigma Initiatives

Bottom Line Streamlines Operations Helps
establish a consistent paint finishing process
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How it works
ChemOPS Operational Flow
Real-time data from sensors
Chemical Bath Monitor, Analyze and Control
Spray System Monitor and Analyze
Graphical Reporting Troubleshooting Cost
Reports Data Reports - Chemicals - Comparative
runs - Water - Point analysis - Gas -
Maintenance logs - Waste water - Alarm logs -
SPC reports
Wireless Communications Quick Alerts Problem
spotting and correction Data entry and
titrations iNet Communications Software
Complete pre-treatment washer control
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ChemOPS Complete System Monitoring
How it works

• Paint Booth (EV)
• Temperature
• Humidity

• Pre-Treatment Washer
• pH
• Conductivity
• Temperature
• Nozzle condition
• Water solenoids
• Chemical drum levels
• Chemical tank levels
• Chemical feed pumps
• Chemical usage

• Utilities
• Gas usage
• City water usage
• Waste water usage
• Waste water pH

• Ovens (Dry-off/curing)
• Temperature

• Production
• Conveyor speed
• Line stoppages
• Parts processed

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Historical Data Logging Reporting
How it works
Alarm Pareto
Xbar and Range
Conveyor Downtime Trend
Conveyor Downtime Pareto
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Continuous Improvement Services
Extended Services
Take advantage of trained and experienced paint
system experts

• Experts work with your paint finishing staff to
• Address issues and identify trends
• Reduce line stoppages and increase first pass
  yields
• Increase product quality and production
  efficiency
• Reduce operating cost
• PLOT (Paint Line Optimization Team) Facilitation
• Team approach to problem solving
• Addresses key strategic tactical performance
  indicators
• Paint System Blueprint
• Monthly run-time data and process analysis
• to identify trends and areas of opportunity
• Continuous improvement action plan

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ChemOPS Installation Tennant Company
Case Study

• 8-stage iron phosphate pre-treatment washer with
  laser-oxide removal
• Centralized Supervisory System Control
• Automatic control of chemical concentrations,
  conductivity, pH, pump pressures, temperatures,
  waste water
• Automatic historical data logging, production
  reports and SPC
• Wireless PDA monitoring and remote alarms
• Utility monitoring / reporting

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ChemOPS Installations Graco and Ekon
Case Study

• Graco Industrial Products (Product Manufacturer)
• Benefits ChemOPS provided
• Increased production without adding staff
• Increased paint finish quality yield
• Reduced chemical costs
• Achieved ROI in 9 months

ChemOPS enabled us to control our paint
finishing system. We now run with higher quality
and increased production. Brian Clancy, Paint
Line Supervisor Graco Industrial Products

• Ekon Powder (Painting Job Shop)
• Benefits ChemOPS provided
• Gained control of paint system
• Dramatic boost in paint finish quality
• Traceable quality records
• Won large new client

ChemOPS provided immediate benefits. It was
like turning on a light bulb and was also
instrumental in helping us win a large
account. Scott Landgraf, Owner Ekon Powder
Coating, Inc.
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Getting Started
Start-up
Increased Production Increased Yield Increased
Quality Reduced Labor Reduced Costs Quality
Reports Controlled Process Continuous Improvement

• Purchase Options
• Buy or Lease
• Installation
• Customer-installable
• Easy plug and play cables
• Includes
• Project management, documentation and training
• Pre-installed / custom configured software
• 3-months Paint System BluePrint Service

Fast start-up and pay-back
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Optional Features and Services
Options

• Quality Tracker
• Reports on pre-treatment and other parts of the
  paint finishing system
• Line Density and Square Foot Monitor
• Assesses square foot processing and parts density
• Wireless PDA alert software
• Enables on-the-belt communications with paint
  staff
• iNET Web Server software
• Enables remote access to view and control paint
  operation
• Extended Services
• PLOT (Paint Line Optimization Team)
• Short-term focused services to address key
  strategic and tactical performance indicators
• Paint System Blueprint
• On-going monthly analysis to identify/correct
  trends and formulate a roadmap for continued
  improvement

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ChemOPS Advantages
Summary

• Quick ROI payback
• Continuous process improvement programs
• Wireless PDA and remote communications
• Upgradable on existing paint systems
• SPC Compliant
• Historical data logging and reporting

Automated pre-treatment washer controller