Customer in Focus: Revolutionising Paint Automation at SMR Lonsdale

SMR Lonsdale, a division of the globally recognised Motherson Group, has long been at the forefront of automotive component manufacturing. As one of the world’s fastest growing suppliers to the automotive industry, Motherson delivers high quality products to major car manufacturers worldwide, including rearview mirrors, lighting systems, decorative trims, and complex wiring solutions. Their commitment to advanced manufacturing processes has driven them to continually explore innovative automation technologies.

Automated Solutions Australia (ASA) has a long history with SMR dating back to its days as Britax Rainsford, and later Schefenacker, before being purchased by SMR in 2009. Britax installed the very first FANUC Paint Robot, back in 1999 – the only RJ2 controlled P-200 in Australia. ASA installed the second unit in 2004, and subsequent units in 2008 and 2023.

Faced with the need to meet the growing demand from new contracts with automotive manufacturers, SMR turned to ASA for a robotic solution. They sought an efficient way to spray small automotive components with full 360-degree coverage. Traditional robotic paint applications, where a robot mounted spray gun moves around a stationary part, were not ideal for this task. The complexity of positioning multiple small parts for complete coverage, combined with the logistical challenges of transferring components through the paint booth after application, made it clear that a more advanced solution was needed.

Working closely with SMR, ASA collaborated on the development of an innovative racking system that enables the robot to remove parts from the rack and present them to a fixed paint applicator mounted on the wall. ASA believes this groundbreaking approach may mark the first remote Tool Centre Point (TCP) paint application in FANUC’s automation history, achieving unparalleled consistency and efficiency in the painting process.

Implementing this unique approach required a series of technological advancements. This was an unprecedented method in robotic painting, demanding a fresh perspective and innovative engineering. FANUC America provided all the necessary expertise in developing, implementing, and rigorously testing the specialised software to ensure optimal performance. The robot’s motion paths were meticulously created and refined to ensure seamless operation.

To optimise the programming of these motion paths, SMR adopted Paint Pro, FANUC’s specialised offline programming software for robotic painting applications. Paint Pro allows users to create, modify, and refine painting paths in a virtual environment before applying them to the actual robot. This capability was instrumental in fine tuning the new paint application method.

Ged McQue from SMR, Motherson Group, was initially exploring the option of transitioning to Paint Pro, preferring the familiarity of making adjustments directly on the teach pendant. “At first, I was more comfortable making changes on the teach pendant,” Ged explained. “It felt like a shift, but with the guidance and support from the ASA team, I decided to give Paint Pro a go. Since then, I’ve been really impressed with its capabilities. I’m now confident making changes directly in Paint Pro, and I’ve found it to be a highly effective tool that has significantly enhanced our processes. I now solely use Paint Pro for adjustments, as it provides a more efficient and streamlined workflow.”

“ASA’s flexibility throughout this project was invaluable” continued Ged, “As timelines and requirements evolved on our end, the team at ASA adapted seamlessly, ensuring the best outcome. They remained flexible in meeting our changing needs, and their commitment to delivering quality was unwavering. We have a long history of collaboration with ASA, and this project marks another significant achievement in our ongoing partnership.”

Michael Boonzaayer, Paint Process Manager at ASA, highlighted the key advantage of this new system, stating;

“The greatest benefit of this innovation is the exceptional consistency it brings to the painting process. Previously, SMR’s system lacked any form of flow feedback, making it difficult to achieve uniform results. By integrating advanced robotics with FANUC’s specialised Paint Pro software and Accuflow technology, we can now dynamically maintain a precise flow rate of 60cc per minute, even when paint viscosities fluctuate. This breakthrough ensures consistent coverage across all parts, significantly improving product quality and production efficiency. It’s exciting to be part of a project that pushes the boundaries of industrial automation, and the results speak for themselves.”

This project not only demonstrates SMR’s commitment to innovation but also showcases the strength of their partnership with ASA. By continuously pushing the boundaries of automation technology, SMR is ensuring their manufacturing processes remain at the cutting edge of efficiency and quality.