For decades, Regal Finishing has earned a reputation for delivering high
quality coatings in applications where consistency and performance are
critical. As product complexity increased and quality expectations rose,
Regal’s traditional painting operations became increasingly difficult to
manage. Multiple paint lines, excessive part handling, and rising scrap levels
needed to be resolved so the company’s growth could continue.
To overcome these challenges, Regal Finishing partnered with Robotic Technical
Support Services (RTSS) and FANUC America to design and implement a fully
automated robotic paint line. The objective was straightforward: consolidate
painting into a single, end-to-end process that would improve consistency,
reduce waste, and increase throughput while maintaining the level of quality
customers expect.
The new system, integrated by RTSS, features FANUC P-50iB paint robots arranged
in a multi-zone, conveyor-fed layout. This configuration allows Regal to apply
multiple coatings — primer, base, specialty finishes and clear coat — in one
pass. By consolidating operations into a single line, Regal dramatically
reduced part handling while improving first pass quality and overall
efficiency. Just as important, the modernized facility reflects Regal’s long
term commitment to advanced manufacturing and continuous improvement.
Since implementing the automated paint line, the company has seen significant
measurable improvements across its operation. Previously, the process required
six painters across four manual paint booths and two older automated lines.
A review of two part numbers being produced by Regal and show the benefits of
the collaboration with RTSS collaboration shows.
Part #1:
- Prior to the new robotic paint line about 150-175 pieces were produced per
shift.
- After integration of the new automation system, production ramped up to
about 300-350 pieces per shift.
- That’s a 133% increase throughput and approximately a 35% improvement in
first run good parts.
Part #2:
- Prior to the new robotic paint line, production totaled about 300-400
sellable pieces per shift.
- After integration of the new automation system, production is about 600 –
700 sellable pieces per shift.
- That’s approximately a 75% increased throughput and about a 35% increase in
first run good parts.
Labor and Material Savings, and Line Utilization:
- Produced 50% salary savings, down from six painters to only three operators
required.
- Paint material usage has seen about 10-15% cost savings.
- Including increased throughput, and the line has availability for about 33%
more utilization.
Not only does the data show greater output and lower costs, but it also means
increased profits and greater confidence in meeting customer demand.