Paint & Primer Optimization
Chemico was hired to develop a chemical lifecycle management program for an aerospace components manufacturer to improve their quality compliance program, inventory control, and an overall reduction in waste and cost. The site included a wide variety of operations including metalworking, painting, electronics, assembly, and testing with multiple departments creating challenges in control and communication. Chemico, program supported the customer through a broad scope of work:
Integrated Chemical Management
Waste and Environmental Management
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Quality Inspection
POU Management
Inventory
Management
Shelf Life
Management
Technical Process
Expertise
Productivity
Improvements
Our team is focused on productivity improvements delivering over 120 projects with an annual value exceeding $1.5M (cumulative $9M). One of the largest and most intricate projects was the Paint & Primer Optimization and Reduction Project. With our team looking into a waste reduction for the site, the various paint/coatings departments were identified as an area to yield significant savings. Chemico works with the various customer stakeholders to address such a complicated product group: Procurement, Environmental, Production Planning, Material Management, and the Production/Operators.
BOM Verification
Every individual paint was verified with each BOM to ensure it was required in the current production process. Those that were not required were removed from the BOM and inventory management plan
Minimum Order Reduction
Chemico was able to reduce the minimum order quantity through our supply chain. Our team also applied part grouping and sharing with other customer sites.
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Demand Planning
Chemico established a formal communication with each department to verify product forecasts monthly to ensure inventory levels, forecasts, and pending orders were adjusted to optimize delivery and material shelf life.
Project Results:
Improved product quality and flow-down compliance
Reduction in annual paint consumption/ waste by 4,800+ gallons – 75% reduction
Product consolidation – Reduced number of Paints
Optimized departmental communication