Painting in Partnership: Regal Finishing Elevates Its Paint Operations with RTSS’ Automation Solution

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.

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.

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Our customers and potential customers can see we’re committed to the future. Our willingness to commit to automation makes a statement that says we’re going to be around a long time.

Jim Kodis President – Regal Finishing