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Issues with the switch to water-based products with poor standards and batch-to-batch consistency.
In an attempt to move away from solvent-based coatings, Symphony Group found a water-based coatings supplier yet faced issues with the finish quality and batch-to-batch colour consistency. In understanding Symphony Group's existing processes, Kortec reviewed areas whereby essential improvement can be made to reach their short-term and long-term goals.
Analysis
Assessment of all aspects of the coating process
When we first started working with Symphony Group they had a range of approximately 20 standard colours which required high standards of colour consistency from batch-to-batch production. All their procedures and quality control were in place but as they made the switch from solvent-based to water-based coatings (with a previous supplier), they experienced finish quality and colour consistency issues that needed to be resolved.
Implementation
Optimised machinery to improve finish quality
Our great level of experience dealing with water-based products enabled us to work closely alongside Symphony Group to find a solution that would provide them with a quality finish and colour consistency. The team optimised the spray/cure machine settings to improve the finish quality and implemented strict quality controls to ensure accurate/consistent colour matching going forward.
Related Article: 'Save £1000’s, How Much Does A Water-Based Coatings System Cost?'
Ongoing Client Benefits
Increase in output and reduction in staffing costs
Since the implementation, Symphony Group has achieved a 50% increase in production output whilst reducing spray shop staff by 30%. Additionally, their colour match rejects rate is down to less than 0.5% which is a huge achievement in comparison to previous batch-to-batch inconsistencies. Kortec continues working closely with Symphony Group and has recently received FIRA Gold Accreditation.
