Reducing Sanding Time by 50%: RC Industries Uses Automation to Improve Finish Quality

For RC Industries, maintaining consistent finish quality across its custom metal products is critical to serving customers. However, as production demands increased, the company’s manual sanding process became a growing operational constraint.

Sanding was performed by hand using dual-action sanders and grinders across multiple shifts. The process required multiple operators and exposed them to repetitive motion, vibration and airborne particulates. At the same time, RC Industries faced ongoing challenges attracting and retaining workers for such a physically demanding role. 

Manual sanding also introduced variability into the finishing process. Operators could unintentionally over-sand or under-sand parts, leading to inconsistent cosmetic quality and inefficient material usage.

To address these challenges, RC Industries was connected to FANUC authorized system integrator, Complete Solution Robotics (CSR), by the University of Notre Dame's iNDustry Labs, which brings together technology partners, regional industry members, and the university's faculty and students to drive innovation, knowledge and impact. Together, the team evaluated an automated solution with the goal to reduce labor strain, improve process consistency and create a more efficient, scalable operation.

The resulting system features a FANUC M-710iC/45M robot integrated into a two-station sanding cell. While the robot sands one part, an operator can unload and reload another, enabling continuous operation and improved throughput. For high-mix production, operators scan a barcode tied to each work order, allowing the system to automatically adjust sanding paths. A user-friendly human-machine interface provides additional flexibility to fine-tune parameters as needed. 

Since implementing automation, RC Industries has achieved measurable improvements. Sanding time has been reduced by up to 50%, while overall production throughout is up to two times faster than manual processes. Production costs tied to sanding have decreased by approximately 55%, and the system now requires just one operator per shift, freeing up employees for other tasks at the facility. 

“Automation was an ideal solution to take a very difficult job and make it more attractive to workers who want to interact with advanced technology rather than perform repetitive manual labor,” said Chris Curtis, owner of RC Industries.

In addition to improving efficiency, the robotic system delivers consistent, repeatable results, eliminating variability in the finishing process while reducing media usage. With a 33% increase in capacity, RC Industries is better positioned to meet customer demand, support future growth and create a safer, more sustainable work environment.  

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Automation was an ideal solution to take a very difficult job and make it more attractive to workers who want to interact with advanced technology rather than perform repetitive manual labor.

Chris Curtis Owner – RC Industries