OTC Supports Automotive Customer with Expert Cleaning and Coating Services in New Facility for a Seamless Start

Overview:

Universal Axle recently opened a new production facility in Cloverdale, VA, and partnered with OTC to perform a Pre-Commission Clean and apply Paint System Coatings. This partnership aimed to protect facility assets, control dirt and debris, and enable easier cleaning.

• Industry: Automotive/Manufacturing
• Relationship with OTC: New Customer

Challenges:

1. Preparing a New Facility: Universal Axle required a complete technical clean for their new production booths, ovens, and surrounding areas before production launch.
2. Protective Coatings Application: The paint booths needed various coatings (white multi-mask, clear multi-mask, and flash tacky films) to protect surfaces from paint overspray and high-traffic wear.
3. High Levels of Dust and Debris: Mechanical installation of new equipment left dust and debris on ductwork, trusses, and in paint system enclosures, risking contamination of final products.
4. Equipment Commissioning and Training: Universal Axle needed assistance with the installation and proper operation of Fanuc robots, automated application equipment, paint pumps, and manual spray tools.

Solution:

To support their upcoming production schedule, Universal Axle’s selected OTC to perform on-site assistance from December 2–December 7, 2024, ensuring the facility was fully prepared for the commissioning of its new paint system and associated oven equipment.

OTC deployed a team of experienced technicians to:

1. Thoroughly Clean All Surfaces: Using vacuum systems, tack cloths, and alcohol wipes, OTC removed dust and debris from booth interiors, oven walls, ductwork, and overhead trusses.
2. Apply Protective Coatings: OTC installed white multi-mask on booth walls, Clear multi-mask on booth windows, and flash tacky film on high-traffic breezeways and oven entrances
3. Protect the Flooring: High-temperature floor paper and tar paper were laid down in critical areas to catch overspray and debris, safeguarding the new facility flooring.
4. Support Equipment Operations and Training: OTC provided on-site guidance and training to ensure proper installation, commissioning, and operation of all paint application equipment, including automatic and manual systems.

Results:

By delivering a meticulous cleaning of the facility and applying protective coatings, OTC significantly reduced dust and debris, ensuring a high-quality, contaminant-free environment. With thorough equipment commissioning support, Universal Axle was able to meet and exceed production start-up targets. In addition, the proper installation of coatings and filters, coupled with comprehensive on-site training, minimized downtime and mitigated potential quality defects. Ultimately, OTC’s presence went beyond fulfilling a contract, demonstrating a commitment to true partnership by understanding, supporting, and enhancing Universal Axle’s production processes.

OTC in Action

Scroll through the image gallery below to see OTC’s work performed with Universal Axle

Universal Axle has opened a new production facility in the Cloverdale, VA area and partnered with OTC for the Pre-Commission Clean and application of Paint System Coatings to protect the asset, capture dirt, and ease in cleaning.

OTC provided the necessary supervision, technicians, equipment, materials and supplies to perform technical cleaning and application of protective coatings for the Pre-Commissioning of the paint system and associated oven.

OTC supplied the clear window film in bulk, that they then cut and installed, proving to be the most cost-effective solution.

Above is the finished application of white multi mask protective coating on the booth exit between automatic and manual booths.

This before and after photo indicates the condition of the duct work before the cleaning process began (left) and showcases a portion of the duct work had been vacuumed (right), prior to the tack cloth and saturated wipe final cleaning. 

Here is the full “after” photo from the finalized cleaning process for exhaust duct work that was shown covered in dust and debris in the previous image.

This photo shows the final cleaning of the booth exhaust duct work on ground level.

Here we see the installation of high temp catch paper installed in the flash tunnel floor between the manual spray booth and oven. This helps keep the new, clean surface of the plant floor free of any paint drips or debris that may occur in the finishing process.

The OTC team cleaned the vestibule windows in preparation for white multi mask to be installed.

Here OTC personnel installed flash tacky on the breezeway entrance and exit. This material is critical as is a high traffic area, thus creating dust and debris that could potentially cause quality defects in finished products.

This photo indicates the installation of tar paper in the vestibule areas of the manual and automatic booths.

Here we see the intake filters of the manual and automatic booths. OTC provides the material and assists in the proper installation of the materials provided.

The incorrect size of P-Clips were originally purchased, inadequately securing the final filters. Our team’s expertise identified this issue and purchased the correct P-Clips to ensure the filters were properly secured.

Here is what a customer can expect from OTC personnel with the final installation of materials within a spray booth. Quality and efficiency are important to us!

This photo shows the final cleaning of the outer booth and oven walls as outlined in their scope of work.

OTC personnel vacuumed and cleaned the oven plenums where dust and debris had collected in the mechanical installation process.

The team cleaned the enclosure roofs and trusses above the paint system. OTC staff used vacuums to catch the heavy dust and debris, then used tack cloths to catch the medium particle, and lastly, saturated wipes were used to give the customer their desired end result of a quality product ready for production.

This photo indicates the final cleaning result of the duct work and trusses above the booth and oven. This is type of quality results a customer can expect from OTC.

This photo indicates the final cleaning of the oven entry prior to high temp tacky film being installed, which will be shown in the next photo.

This photo indicates the final installation of the flash tacky film on the oven entrance, while also showing the high temp floor paper that protects the floor from booth exit all the way to oven. OTC assists in the installation of the products, while also adequately prepping the entry and exit to indicate the finished product is complete and commissioning is adequate.