Cummins Kent – Automated Spray Facility
Cummins Inc. is an American fortune 500 company with a turnover in excess of $19 billion, involved in the design and manufacture of diesel engines and power generation products. At their site at Manston, Kent, they carry out final assembly of packaged power generation products. The generator sets consist of a diesel drive engine, alternator, fuel tanks, ancillaries and control systems, all mounted onto a fabricated steel chassis or ‘bed’. These can then be shipped anywhere in the world to provide an efficient, reliable source of electricity.
Cummins approached ISS with a need to increase their productivity on the manufacture of chassis beds for generator sets. The painting process was proving to be a bottleneck, their current system consisted of operators manually spraying beds and allowing them to naturally air dry. This was leading to stacks of fabricated beds being held up during paint.
From the early stages ISS worked with Cummins to understand their process and what production rates they wanted to achieve. It was clear that their current production facility did not have the physical space required to accommodate a plant that would be able to deal with the required throughput. ISS proposed an external facility to be built next to their fabrication shop, to house an automated spray facility incorporating the following plant:
- Primer Spray Booth – Full Down Draught Extraction with Heated Air Replacement
- Primer Oven
- Top Coat Spray Booth – Full Down Draught Extraction with Heated Air Replacement
- Top Coat Oven
- Paint Mixing Room
- Paint Storage Facility
- Power & Free Conveyor System
All of this was housed in a steel portal frame building that was designed and contracted by ISS.
The system allowed Cummins to increase production rates to keep up with fabrication and assembly, and provided them with a first class manufacturing plant that complied with all relevant HSE and Environmental regulations.
The power and free conveyor system was integral to the process, as TAK times between stages varied significantly. This system allows beds to be ‘stacked’ in the ovens while other beds are allowed to move freely around the system. This allowed ISS to keep the system compact and the heated sections as small as possible, increasing energy efficiency.
A sophisticated PLC control system was installed, with an advanced HMI screen, allowing the operators to control all aspects of the system from a single point and monitor the position of products on the conveyor. A remote link was installed between the panel and ISS head office to allow for remote fault finding and support if necessary.
As part of the conveyor system ISS designed and manufactured a bespoke rotation jig that allows operators to rotate the beds (Weighing in at up to 5000kg each) with ease to access all sides for painting, again leading to an increase in productivity.
ISS Production Director Steve Todd described the project:
This project was seen as major success and is just another chapter in the long working relationship ISS have with Cummins in the UK, where we have worked with them on 7 different projects, each time providing a first class system to meet their specific needs. It was a great effort by all involved and has produced a fantastic plant, one which both Cummins and ISS are immensely proud of.
Cummins Manufacturing Service Leader Keith Stoneystreet Praised the Efforts of ISS:
ISS have provided fantastic customer service throughout this project, bending over backwards to meet the requirements of Cummins and always going the extra mile to ensure that this plant met the strict needs of our production requirements. No other company that I have worked with during my time at Cummins has been so accommodating to our needs. This dedication and the confidence it has instilled to us in ISS shows in the repeat business that Cummins has awarded to ISS at our sites across the UK.
ISS offer a wide range of bespoke products, as well as being able to design, build and install custom installation such as this to suit any requirement, timeframe and budget.
To discuss your requirements please call 0161 653 0700 or email email@example.com
- • Client – Cummins Power Generation
- • Location – Manston, UK
- • Product Type – Fully Automated Spray Facility
- • Project Date – June 2014
- • Project Value - £ 900,000