C81: Using AI to Build Process Intelligence in Powder Coating

Long‑term powder coating performance depends less on new technology and more on maintaining consistent line health. In many operations, instability begins with small variations such as uneven gun output, worn components, drifting electrostatics, inconsistent air pressure, or changes in part presentation. When these issues are addressed reactively, efficiency, consistency, and first‑pass yield gradually decline. This session presents a practical, operator‑driven framework for maintaining coating line health through structured maintenance and fine‑tuning routines. Drawing from real production environments, attendees will learn how to standardize gun setup and checks, detect early signs of wear, use pre‑cure film thickness as a health indicator, and reduce shift‑to‑shift variability. The focus is on disciplined routines and measurement‑based decision making to improve stability, reduce rework, and sustain performance over time without major capital investment.