Last year, NAIP Reco-Steel launched a project aimed at reducing the cost of painting reconditioned steel drums. They established a system where paint booth operators use tablets to input paint mileage data into the UPKEEP CMS. This initiative not only ensures consistent tracking of paint usage but also provides live data that streamlines procurement processes and enhances the efficiency and effectiveness of maintenance activities.
The primary benefit of tracking paint mileage is to ensure consistent paint usage and eliminate waste. Dry film thickness is measured at three points on finished drums (top third, middle third, and bottom third) to ensure uniform coverage without excess paint, thereby reducing material costs. This tracking also provides accurate data for inventory counting, RFQs, and scheduling preventative maintenance. Productivity is enhanced by having operators input data into a live tracking system, making information readily available and alleviating the need for manual collection and calculation.
The project was launched in July at the Galena Park, Texas facility within the Reconditioning West division and rapidly expanded to all North America Reconditioning – Steel within three months. Weekly reports and monthly check-ins are utilized for predictive maintenance, monitoring progress, and sharing best practices among teams to ensure continuous improvement and success.
The initial implementation resulted in $286,000 in savings in 2024. With full implementation over a complete year, the project is expected to yield over $1.2 million in annual savings starting in 2025.
This idea was initially proposed by Daryl Johnson, Reco Division Quality Manager. However, successful implementation was achieved through the collaborative efforts of various teams, including quality, continuous improvement, procurement, and plant managers, under the leadership of David Vanvoorhis, CI Project Manager, and Yao Xie, Senior Sourcing Category Manager.
“Great work by everyone involved to turn an idea into real cost savings and process improvements for Reco Steel!”