Custom masking solutions, while requiring a higher up-front investment, can significantly enhance operational efficiency and long-term profitability. Many companies hesitate to transition from standard, off-the-shelf masking products due to perceived cost concerns. However, does this approach truly save money over time?
In discussions with industry professionals, masking has consistently been identified as one of the most time-intensive tasks on a paint line. Despite this, masking innovation is often overlooked in favor of traditional options like tapes, caps, and plugs readily available from numerous suppliers. While custom masking does come with initial costs, these are frequently offset by substantial labor savings realized in just days or weeks.
Take, for example, a part prepared using two methods: standard green polyester tape versus a custom die-cut kit. With standard tape, masking took 30 minutes, compared to just five minutes with the custom solution. Adjusting for the efficiency of a skilled operator, the times were closer to 10 minutes versus two minutes. At an unburdened labor rate of $20 per hour, the labor cost difference alone is striking.
Beyond labor savings, custom masking can boost productivity. Consider a scenario where a part is billed at $25 for coating. Faster masking allows for a greater volume of parts processed per hour, leading to increased revenue potential.
Custom masking also reduces indirect costs such as internal rework, scrap, and Cost of Poor Quality (CoPQ) charges. One customer reported losses of $10,000 per week due to scrapped and reworked parts from inadequate standard masking. Another faced a $300 penalty per item because of the results from insufficient masking. When these costs are factored in, a $2,500 tooling charge for custom masking quickly becomes a sound investment.
In summary, while catalog masking items may seem economical, the hidden costs—lost time, reduced throughput, rework, and customer dissatisfaction—can outweigh any initial savings. Time studies often reveal unexpected insights, making it worthwhile to explore custom masking options with experienced providers who can help improve efficiency and profitability.
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