Process improvement in industrial paint manufacturing: A case study on Monocoat production

This thesis explores the efficiency improvements in Monocoat production at the PPG Industries Quattordio plant. Monocoat is a specialized single-layer paint designed for industrial applications, offering benefits in sustainability, cost reduction, and production efficiency. Unlike traditional multi-layer coatings, which require multiple application steps, Monocoat simplifies the process, enhancing productivity while upholding high-quality standards. The study provides a thorough analysis of the Monocoat production process, including the stages of dispersion, grinding, binder, and final completion. It identifies inefficiencies in material handling, automation, and process flow, proposing targeted optimizations. A significant focus is on the integration of the Macromedia system, which enhances the pre-dispersion and grinding phases, reducing overall production time while achieving the necessary fineness and homogeneity of the final product. Additionally, the research examines improvements in automation, raw material handling, and workflow streamlining to minimize waste and increase throughput.