Our customer was a global tire manufacturer. He wanted to replace an old worn out spray machine that was manually loaded with a new piece of equipment that could be conveyor fed with improved spray characteristics and reduced labor.
Another challenge was the variation of tires through the spray system. To minimize Work-in-Process, the tires would no longer be produced in batches stored on tire carts but enter the system completely randomly via a conveyor system.
Thankfully, our customer had been introduced to Pioneer Industrial Systems through prior projects at other plants. After a brief discovery call, a sales engineer was on-site within a week to further understand the challenges, constraints, and requirements of the system.
Our engineers have been working with the tire industry since the late 1980s, so we understood the importance of minimizing overspray, meeting high-speed cycle time, and spraying a wide range of tire sizes. This plant primarily built passenger tires, so a DTS1000i would be perfect for this application.
Since the plant had two older Dial Index Tire Spray machines, it was determined to stay with a rotary style DTS machine, but one that could provide more output and improved spray characteristics.
A project that we had completed about four years prior had involved a fully enclosed spray booth that included many other benefits.
Pioneer had completed several successful tire spraying machines, white wall spraying machines, tire marking machines that operated in a dual-mode, with both recipe and adaptive intelligence. This dual-mode resulted in a precise spray and maintained consistent uptime, with tires entering the system entirely at random.
After discovering the customer’s needs, the sales engineer provided the customer with a proposal that included advantages of our PFDS and cycle time analysis. With this data, the customer was able to sell the tire spray machine to leadership easily. It was approved within the budget, met the required specifications, and a PO was issued.
Pioneer started its defined Machine Building Process. After the customer runoff, the machine was disassembled, shipped, and Pioneer’s assembly crew went on-site to install the equipment. The engineer then stayed on-site the following week to connect our system to the plant conveyors and higher-level server and a few days of commissioning and training.
The customer was given support documents and was well taken care of after the startup was completed.
Overall, the project was very successful. The system was installed on schedule. The spray was contained with minimal to no overspray getting outside of the spray booth.
Cycle times were better than initially anticipated.
The plant engineer was involved throughout the project, so he was always aware of status, any obstacles and felt comfortable throughout the entire process.
Mold release consumption was considerably lower than comparable machines due to our Precision Fluid Delivery System, which was a substantial cost savings.
The machine performed so well that the plant wants to replace the second unit as soon as they can get their budget approved.
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