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:
- Preparing a New Facility: Universal Axle required a complete technical clean for their new production booths, ovens, and surrounding areas before production launch.
- 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.
- 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.
- 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:
- 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.
- 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
- 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.
- 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