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About the Lean Coatings Audit(TM)

Conducted by an experienced team of chemists and technical service personnel, the Lean Coatings Audit™ can be completed in about two hours. We will interview your key personnel to identify opportunities to reduce your coatings-related costs. We focus on the following dimensions of the coatings process:

• Economic Order Quantity
• Transportation
• Storage
• Application and Transfer Efficiency
• Performance
• Product/Equipment Matching
• Labor
• Curing
• Waste Minimization and Recycling
• Environmental Compliance and VOC/HAPS Reduction
• Waste Disposal
• Container Recycling

Here are some examples of how Jamestown’s expertise is helping our customers boost their profitability:

Aleris Light Gauge, a leading aluminum-packaging products manufacturer, was operating at capacity, or so they thought. They asked Jamestown to perform a Lean Coatings Audit™ to see where they could reduce costs. Jamestown responded by developing a coating that could be cured at a lower oven temperature. This enabled Aleris to reduce their energy consumption. We also discovered that Aleris could increase their line speeds by 50%. The faster line speeds allowed Aleris to add capacity without a single dollar of capital expenditure.

The world’s premier producer of underground mining equipment, Joy Global, needed to reduce emissions and consolidate their paint purchases across a multitude of global manufacturing facilities. They turned to Jamestown to help them achieve these goals. Jamestown developed a waterbased coating that met Joy’s performance demands, was more environmentally friendly, and could be applied using a several different spray systems. Now, instead of a different coating for each location, Joy is using the same waterbased coating at each of its manufacturing and service centers.

Mack Trucks (now Volvo) needed a single coating that could be applied to their truck engines. Jamestown evaluated their coatings process and discovered an opportunity to help Mack reduce its emissions. The waterbased coating we developed can be applied to cast iron, plastic, steel and aluminum (all present on Mack’s engines) with excellent adhesion and performance. This allowed Mack to coat their engines after assembly, instead of piece-by-piece, prior to assembly.

Deluxe Corporation was looking for ways to reduce their coatings costs. Jamestown helped the shelving manufacturer capture their overspray and return it to Jamestown. What was previously considered hazardous waste was able to be recycled. We turned the collected overspray into a fully functional coating that could be applied to Deluxe’s products – just like virgin coatings. Deluxe reduced their waste disposal costs and lowered their coating cost-per-part.