For powder coaters looking to reduce powder consumption by a guaranteed 10% and enhance their operations, Blueprint™ OS offers a straightforward onboarding process that delivers immediate impact.
It begins with an initial consultation, where we explore operational pain points and goals. From there, clients can move to a hands-on demonstration phase, providing a risk-free opportunity to evaluate the system’s potential impact.
The Onboarding Process: Step by Step
During the on-site demo, our team analyzes our clients’ current operations, running benchmarks to evaluate performance metrics and identify improvement areas. At the end of the demonstration, the clients will receive insights into measurable powder savings and performance enhancements. If satisfied, they can immediately proceed with full onboarding, optimizing both major and secondary powders while ensuring production continuity.
Onboarding Step 1: Video Call with coatingAI
The onboarding process begins with a video call aimed at assessing whether our technology is the right fit for the client. During this call, we work closely with the client to understand their specific challenges and identify which issues Blueprint™ OS can address. We also explore their current processes and discuss how Blueprint™ can integrate into their operations.
After identifying which problems Blueprint™ OS can solve for our clients, we provide clear pricing details aimed at achieving a return on investment in the following months. Our clients can then choose to proceed with an on-site demonstration, which carries no obligation to purchase if the results of our demo do not meet their expectations.
Onboarding Step 2: On-Site Demo at Your Convenience
The on-site demonstration evaluates our clients’ operations and showcases the potential impact of Blueprint™ OS. Our team will visit your facility, spending time on the production floor to observe and analyze your existing processes. This includes walking through the workflow, taking detailed measurements, and benchmarking key performance metrics.
Once the initial evaluation is complete, we move on to the demonstration phase. This requires a brief interruption of the production process, typically lasting no more than 15 minutes, to implement and test our solution. By the end of the demonstration, you’ll gain clear insights into potential improvements in efficiency and powder savings.
Onboarding Step 3: Powder Usage Optimization
The final step is where we optimize our clients’ coating line to demonstrate powder savings. The powder usage optimization phase builds on the insights gathered during the on-site demonstration and focuses on achieving measurable improvements in efficiency and powder savings. Here’s a summary of how the demo typically unfolds:
- Arrival and Initial Meeting: Our team arrives on-site and begins with a brief meeting to outline the day’s agenda, ensuring alignment with the client’s expectations and goals.
- Production Walkthrough: We walk the coating line, observing the workflow, and reviewing the current processes to identify potential inefficiencies.
- Initial Measurements and Benchmarking: Using precision tools, we take detailed measurements and establish baseline performance metrics for the coating process.
- Short Line Interruption for Optimization: The production line is paused for a maximum of 15 minutes while we implement adjustments and begin the optimization process.
- Post-Optimization Benchmarking: Once optimization is complete, we re-measure and compare results to the initial benchmarks, highlighting the improvements achieved.
- Results Discussion: Finally, we sit down with the client to review the day’s findings, discuss the demonstrated improvements, and outline next steps for full onboarding if the client is satisfied with the results.
coatingAI’s Continuous Support
At coatingAI, we are committed to providing our clients with comprehensive support throughout their journey with Blueprint™ OS. Our system integrates seamlessly into their operations, requiring only a calibration tool and software—no significant disruption or additional equipment investment is necessary.
After the initial setup, coatingAI’s team conducts monthly visits to ensure our clients’ systems remain optimized. These visits are streamlined to minimize downtime—typically requiring only 15 minutes of line time per booth for updates and preventive maintenance. We schedule these visits during regular breaks to avoid any production impact.
We prioritize maintaining strong communication with you, our valued client. Our clients’ feedback is essential in helping us refine our services. To enhance our support, we have established a customer success team dedicated to ensuring our clients receive premium service during our monthly visits. This team also reviews the clients’ monthly powder expenditures and provides online training sessions to enhance their experience.
We strive to collaborate not just with engineers but also with purchasing teams at our clients’ facility, so we can better understand how we are making an impact, and maximize powder savings.
How does coatingAI achieve powder savings for its clients?
Through Blueprint™ OS we achieve powder savings for our clients by addressing several key challenges in the powder coating process, focusing on consistency, precision, and data-driven optimization. Many of our clients faced issues with inconsistent product quality, which led to rejects and wasted materials. Our Blueprint™ OS tackles this problem by ensuring that coating thickness is as uniform as possible, reducing both excess material usage and rejects due to coating inconsistencies.
Imagine a coating process with non-uniform powder distribution. The thinnest areas in the coating represent the minimum thickness. Currently, the operator relies on experience to adjust the process and ensure that these minimum areas meet the required specifications. However, the operator doesn’t have a clear view of the overall distribution and is simply measuring and adjusting based on the areas that appear too thin.
This means that the thicker areas of the coating will be much more excessive than the minimum required, resulting in the application of extra powder that serves no purpose. After curing, this excess powder is wasted, as it doesn’t contribute to the part’s quality and cannot be reused. By making the coating distribution more uniform, we eliminate these unnecessary thick areas, effectively saving the powder that would otherwise be wasted.
The Blueprint™ OS improves performance by focusing on thickness distribution across coated parts. During the benchmarking process, multiple thickness measurements are taken to establish an initial spread of values. The system’s goal is to bring these values closer to the target thickness, minimizing material waste while still meeting the minimum coating requirements. Unlike traditional methods, which rely on intuition and experience, Blueprint™ OS uses data-driven decisions to make precise adjustments, ensuring that coatings are not too thick or too thin, which either wastes coating powder or results in rejects
What we have noticed is that many of our clients are unaware of the substantial savings potential by addressing inhomogeneity in their powder coating processes. The focus is often on increasing throughput and meeting minimum thickness requirements by adding more powder, rather than optimizing powder usage. This approach often leads to overspending on powder, especially as the priority is simply ensuring parts are produced and standards are met.
This approach may cause our clients to miss opportunities to refine the process for better efficiency. Blueprint™ OS changes this by providing a deeper understanding of the coating process, helping our clients optimize operations while saving powder. Our data-driven approach leads to better optimization, reducing the amount of powder used while improving quality. By continually refining the coating process, coatingAI helps our clients save powder, lower material costs, and increase productivity, ultimately resulting in significant financial savings and improved operational efficiency.
Does coatingAI’s Blueprint™ OS have Competing Solutions in the Market?
Blueprint™ OS stands out as a unique solution for achieving savings in the powder coating process. What distinguishes coatingAI’s Blueprint™ OS from competing solutions is our unique ability to bridge the gap between existing tribal knowledge, booth manufacturers, and powder manufacturers, creating an intelligent system that truly optimizes the coating process. While there are no direct competitors to Blueprint™ OS, we face indirect competition from various sources, including internal teams’ knowledge, consultants, and even equipment manufacturers. However, Blueprint™ OS is not a replacement for these industry experts; instead, it acts as a powerful tool that complements their expertise, allowing them to work more efficiently and effectively.
Many coating operations rely heavily on internal tribal knowledge, which is often limited and does not evolve with the changing needs of the business. While technicians and engineers have honed their skills over time, they may be resistant to change because they feel that new systems like Blueprint™ OS could undermine their roles. However, Blueprint™ OS is designed to assist and enhance the capabilities of operators and engineers, helping them optimize and equalize their systems to achieve the best coating results with minimal waste.
While booth and powder manufacturers focus on ensuring the quality of their respective products—booth manufacturers ensuring the hardware functions correctly and powder manufacturers guaranteeing the powder’s quality—Blueprint™ OS addresses a different objective. We bridge the gap by ensuring that the hardware is optimally configured for the specific powder in use. Since every powder behaves differently and needs to evolve over time, our solution enables precise adjustments to account for variations in powder, part size, and environmental conditions, offering a level of customization beyond the scope of traditional parameters provided by manufacturers.
What sets Blueprint™ OS apart is its ability to adapt and address the evolving needs of our clients. Over time, we’ve refined our processes to deliver even greater value. For instance, our demonstration process, once requiring four hours, now takes just 30 minutes—reflecting our commitment to efficiency without compromising results. While powder savings remain a key benefit, we have also expanded our focus to address broader production challenges, such as reducing rejects, minimizing rework, and safeguarding our clients’ reputations. This evolution has solidified Blueprint™ OS as a comprehensive platform for enhancing production efficiency and quality control.
Moreover, as we continued to engage with various industries, such as large battery manufacturers, we identified new opportunities, like predictive maintenance and more advanced optimization for vertical lines. Our use of AI enables us to apply predictive models for correlating gun output to coating thickness, which allows us to further refine the coating process, making it more scientific than ever before.
Blueprint™ OS by coatingAI is not just a tool—it is a complete, intelligent system that evolves with the needs of our clients. With AI integrated into key aspects such as process optimization and predictive maintenance, Blueprint™ OS helps our clients move beyond traditional coating methods, transforming their operations into smarter, more efficient systems that consistently deliver better results.
The future of coatingAI: How has Blueprint™ OS Evolved Over Time?
The future of coatingAI is driven by client feedback and continuous innovation. Blueprint™ OS has undergone significant improvements since its inception, with each client interaction playing a crucial role in its development.
Our commitment to listening to our clients has been instrumental in the evolution of Blueprint™ OS. As coatingAI works with more clients, the system is tailored to meet our clients’ unique needs, refining our solutions over time. Rather than focusing on creating new innovations for the sake of novelty, we emphasize addressing real-world challenges, such as improving coating precision and helping clients optimize their operations.
Looking to the future, coatingAI sees a growing opportunity to bridge the gap between our clients’ existing knowledge, booth manufacturers, and powder manufacturers. By integrating AI across all aspects of the coating process, from spray gun calibration to predictive maintenance, coatingAI aims to make the entire system smarter and more efficient. AI’s role in correlating gun output to coating thickness is just one example of how technology can make a real difference, ensuring that customers get the most out of their coating systems.
As coatingAI continues to expand its reach, we are committed to helping businesses of all sizes benefit from Blueprint™ OS. Whether you are already spending significantly on powder or just beginning to optimize your operations, Blueprint™ OS offers immediate advantages in improving both efficiency and product quality. Built on customer-driven improvements and with a focus on refining AI capabilities, the future of Blueprint™ OS is one of continuous growth, innovation, and positive impact across the Powder Coating Industry.
