Efficient layout for high volume repairs
The company mainly carries out small and medium-sized repairs on vehicles returning from long-term rental before they are put back on the market.
The fleet is very large and repairs have to be carried out quickly to prevent the vehicles from remaining there for too long.
Request
The plant needed to be able to quickly process large volumes of vehicles for repair while keeping production costs low.
A smooth layout was needed that would reduce the turnaround time for each vehicle.
Solution
The plant consists of two areas: a vehicle paint preparation area and a complete line from vehicle preparation to painting.
The preparation area consists of two double Genius preparation zones, equipped with under-wheel lifter embedded in the grating, motorized curtains, and infrared and UV drying semi-arc. All controlled by touchscreen PLC for intelligent consumption management and Industry 4.0.
The in-line system allows for a complete repair cycle by easily moving the vehicle by rail car mover.
The vehicle is placed in the control area for initial inspection and disassembly work. It is then transported by trolleys to the preparation zones for the various processing stages (filling, sanding, painting). All zones are equipped with infrared and UV curing media-arches to greatly accelerate the smart repair work.
Next, the vehicle is moved to the Extra spray booth through the motorized side shutter. In the booth, painting and drying operations take place, facilitated by a motorized drying arch that can be programmed via PLC. At the end of the operation, the vehicle reaches the final station to check the outcome of processing.
High-efficiency heating-ventilating units are equipped with inverters and heat recovery, reducing fuel consumption by up to 50% and reducing electricity consumption by up to 30%.
