Manufacturing Publications

PAINT WASTE REDUCTION

LOCKHEED MARTIN AERONAUTICAL SYSTEMS

SUMMARY

Lockheed Martin Aeronautical Systems located in Marietta, Georgia revised their methods for mixing multi-component paints for touch-up and small parts application. The change provided for the mixing of partial multi-component kits in only the quantity needed reducing excess paint waste.

BACKGROUND

Lockheed Martin manufactures military aircraft that require highly corrosive resistant and durable coatings throughout. The specified coatings are multi-component paints that are purchased primarily in one gallon kits. The kit contains an exact quantity of each paint component providing the required ratio for mixing. Once mixed the paint has a short potlife (cure time). Prior to providing a method for mixing smaller than kit quantities, the whole paint kit had to be mixed regardless of the amount needed. It is estimated that one third of the paint mixed was being wasted due to expired potlife. This resulted in hazardous material disposal annually of 2,020 gallons of paint. The company needed to continue to comply with the required stringent material specifications of the paint but wanted to reduce hazardous waste disposal and the associated cost.

PROCESS MODIFICATIONS

Measuring devises such as graduated containers and cups having known volumes were provided. The Manufacturing Processing Standard (MPS) was revised to include methods and specifications for mixing partial paint kits.

RESULTS

The cost to provide methods to measure and mix the specified ratio of paint components, in less than whole kit quantities, totaled $4,000. This change will reduce the company's hazardous waste stream by 2,020 gallons per year while saving an estimated $120,649 annually in waste management fees and paint cost. Below are the estimated savings calculations.

Implementation cost = $4,000

Material cost of paint waste = $47/gal x 505gal/mo x 12mo/yr x 1/3 = $94,940/yr

Waste disposal cost = 505 gal/mo x 1/55 gal/drum x $700/drum x 12 mo/yr x 1/3 = $25,709/yr

Total savings = $94,940 + $25,709 = $120,649/yr

Payback = $4,000/$120,649/yr x 12 mo/yr = .40 months

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