Rockslide Engineering Triples ROI with TITAN-Catalytic and NIKO Conveyors Upgrade

Rockslide Engineering specializes in creating high-quality parts and accessories for various four wheel drive platforms including Jeep, Ford, Toyota and G-Wagen. Known for their commitment to innovation and quality, Rockslide Engineering faced a significant challenge: their outdated batch production system was limiting their capacity for both B2B supply to Jeep Performance Parts, along with B2C aftermarket service to the likes of GM, Ford, Toyota, Ram, and Jeep owners.

The Challenge 

Before upgrading their operations, Rockslide Engineering operated with a traditional batch system. This manual, push-and-pull method required substantial labor and was inefficient, particularly when running extended shifts. The company faced rising demands and needed a solution that could boost production without breaking the bank.

The Solution 

Rockslide Engineering partnered with TITAN-Catalytic, NIKO Conveyors and a California-based system integrator to revamp their production line by incorporating new equipment and automation. The upgrade included the following key components: 

1. TITAN-Catalytic Dry-Off Oven: This oven was crucial for removing residual water from parts after a complex wash system. With a 3-stage wash process occupying 40 feet, the TITAN-Catalytic Dry-Off Oven was configured to ensure complete drying, preventing any moisture from interfering with subsequent processes. 

2. Automated Powder Booth: After the dry-off phase, parts enter the new automated powder booth. Manual labor was replaced with robotics, significantly reducing the need for human intervention in this phase while turning out consistent part quality. 

3. TITAN-Catalytic Pre-Gel Oven: Parts leave the powder booth entering the TITAN Catalytic Pre-Gel Oven. This oven pre-heats the powder-coated parts to ensure a proper gel before they proceed to the new convection oven. Without Pre-Gel the air movement present in a typical convection oven can be detrimental to the coating’s ultimate finish.

4. NIKO Conveyors Overhead Track: A critical component of the new system, the NIKO Conveyors overhead track facilitates efficient material handling through a combination of manual and automated processes. This 50/50 system streamlines the movement of parts through the powder coating and curing stages minimizing worker intervention while maximizing throughput of product.  

5. 40 ft Convection Oven: Before exiting the powered portion of the Niko Track Rockslide added a 40ft inline convection oven that brings the powder to full cure.

Implementation 

The integration of the TITAN-Catalytic ovens and NIKO Conveyors led to a significant transformation in Rockslide’s production process. The company upgraded from a labor-intensive, batch-based system to an automated, streamlined operation. The new system allowed Rockslide to process parts more efficiently, reducing the need for additional shifts and labor while boosting production capacity. 

Results

The results were striking: 

• Increased Production Capacity: Rockslide Engineering tripled their production capabilities. Previously, their batch system handled 120 units per day; the new automated line increased this capacity to approximately 360 units daily. Remarkably, they now operate only four days a week, achieving the previous week’s output in a shorter time frame. 

• Enhanced Quality Control: With automation reducing manual handling, the incidence of defects decreased. The streamlined process improved the consistency and quality of the finished products, despite the higher production volume. 

• Labor Efficiency: The automated system led to a 60-75% reduction in the need for additional labor. Instead of increasing their workforce to handle higher production, Rockslide maintained the same number of employees while significantly boosting output. 

“Upgrading to an automated line has minimized scrap and reduced manual handling of parts. The improved automation chain has drastically enhanced our operations,” said Colton Schenk, Mechanical Designer of Rockslide Engineering. 

Conclusion

Rockslide Engineering’s investment in TITAN-Catalytic’s Dry-Off and Pre-Gel ovens, coupled with NIKO Conveyors’ advanced overhead system, has revolutionized their production capabilities. By moving from a labor-intensive batch process to an efficient automated line, Rockslide not only met but exceeded the demands of their major clients, demonstrating how strategic upgrades can lead to substantial improvements in production efficiency and quality.