The Challenge
Modernizing a Manual Paint Process Without Full Equipment Replacement
The client needed to eliminate manual spray painting due to throughput limits and inconsistent coverage. Their key needs were:
- Automate powder application across full-height booth (~892 mm)
- Strip and re-dip chassis components with repeatable precision
- Fit robotic automation into existing booth and conveyor footprint
- Maintain use of current dip tanks, paint stations, and flow systems
- Integrate controls and safety interlocks with minimal disruption
MWES was selected to retrofit robotics into the powder-coating process—delivering improved performance while extending the life of their current assets.
The Solution
Track-Mounted Paint Robots Integrated with Existing Powder-Coating Line
MWES delivered a fully integrated robotic painting retrofit system that included:
- FANUC Paint Mate 200iA/5L robots mounted on Floortrack—one for strip/de-dip operations and one for coating
- Gema GA02 powder coating guns for precise, uniform application
- Servo lift modules to extend robot reach vertically across booth height
- Custom vacuum/gripper EOAT for handling oily, coated chassis part
- Integration with existing dip tanks and paint flow stations
- Recipe-controlled cycling and timed dwell in each dip tank
- Comprehensive safety interlocks including light curtains and e-stop systems
By retrofitting advanced robotics into an existing line, MWES delivered a cost-effective automation upgrade that improved consistency, efficiency, and safety—without the need for total system replacement.
The Results
Improved Consistency, Reduced Labor & Extended Equipment Life in Powder Coating
This upgraded system delivered tangible improvements:
- Replaced manual painting with automated spray, increasing consistency
- Eliminated direct handling of dripping, oily parts—improving operator safety and ergonomics
- Maintained throughput and booth utilization using existing hardware
- Achieved more uniform powder coverage across part surfaces
- Retrofit cost substantially lower than full replacement of paint cells
- Enabled higher throughput and reliability using familiar infrastructure
By retrofitting advanced robotics into an existing line, MWES delivered a cost-effective automation upgrade that improved consistency, efficiency, and safety—without the need for total system replacement.
