Case Study: How One Painting Robot Saves Our Customer ¥500,000 Annually---An Industrial Automation Success Story
Sep 27,2025
Introduction: The Challenge of Manual Painting Operations
Many manufacturing companies face persistent challenges with manual painting processes, including inconsistent quality, high material waste, and rising labor costs.
For one of our clients in the automotive components sector, these issues were costing them both time and money. Before implementing our painting robot solution, the client relied on skilled workers for spray painting tasks. Despite their expertise, human limitations led to variable output quality, high reject rates, and escalating expenses due to overtime wages and material overuse. The need for a reliable, cost-effective alternative became urgent.
This case study explores how the integration of a single industrial painting robot not only resolved these issues but also delivered annual savings of ¥500,000. By leveraging advanced automation, the client achieved higher consistency, reduced waste, and improved workplace safety. For businesses considering robotic painting automation, this real-world example highlights the tangible benefits of upgrading from manual methods to smart technology.
Client Background: Struggling with Inefficiency and Costs
The client, a mid-sized manufacturer of metal components for automotive assemblies, had a dedicated painting section staffed by six skilled workers. Their process involved manually spraying protective coatings onto parts ranging from engine brackets to chassis elements. While the team was experienced, the manual approach posed several problems:
- Inconsistent Coverage: Human operators could not always maintain uniform spray patterns, leading to uneven coating thickness. This resulted in a 15% reject rate because poor aesthetics or inadequate protection .
- Material Waste: Overspray and inaccurate application caused nearly 30% of paint to be wasted . With high-quality coatings costing ¥200–¥300 per kilogram, this waste significantly impacted profitability.
- Labor Costs and Risks: Each painter earned an average of ¥120,000 annually, with additional costs for protective gear, training, and health insurance. Moreover, prolonged exposure to fumes and repetitive motions raised safety concerns and absenteeism.
The client initially hesitated to adopt automation because perceived high upfront costs. However, after a detailed ROI analysis revealed that a painting robot could pay for itself in under 15 months, they decided to proceed with a pilot installation.
The Solution: Implementing a SZGH Painting Robot
We recommended our model P1500-B-6 painting robot, a system designed for precision and adaptability. Its key features include:
- Ultra-Low Splash Technology: Controlled arc ignition and droplet formation minimized overspray, reducing paint waste by 25% compared to manual methods.
-Free Programming Operation: The most innovative feature was the handheld teaching function. Instead of complex coding, operators simply used a lightweight handheld device to demonstrate the spraying motion manually. The painting robot would accurately record and replicate every movement, creating perfect spray paths without any programming knowledge required.
- Integrated Vision System: The robot’s cameras detected part dimensions and orientation, automatically adjusting spray parameters for complex geometries.
Installation involved three phases:
1. Site Assessment: Our engineers analyzed the production line layout and coating requirements.
2. Integration: The painting robot was mounted on a modular rail system to serve multiple workstations.
3. Training: Client staff learned to operate the system via a user-friendly touchscreen interface.
Within two weeks, the robot was fully operational, working alongside two retained employees who handled loading/unloading and quality checks.
Quantifiable Results: How Savings Were Achieved
The painting robot delivered measurable financial benefits within the first year:
Cost Category | Before Robot (Annual) | After Robot (Annual) | Savings |
Labor Costs | ¥720,000 (6 workers) | ¥240,000 (2 workers) | ¥480,000 |
Material Waste | ¥180,000 | ¥126,000 | ¥54,000 |
Rework/Scrap | ¥90,000 | ¥30,000 | ¥60,000 |
Total | ¥990,000 | ¥396,000 | ¥594,000 |
Net Annual Savings: ¥500,000+ (after accounting for robot maintenance and energy costs)
Additional improvements included:
- Faster Cycle Times: The robot operated at consistent speeds day and night, boosting output by 20% without overtime .
- Enhanced Quality: Coating uniformity reached 98%, reducing client complaints and returns .
- Safer Workplace: Eliminating direct exposure to chemicals improved employee health and reduced insurance premiums.
These outcomes align with industry trends. For example, a construction firm reported 46% lower labor costs after adopting automated spraying , while an aluminum plant saved ¥400,000 yearly with similar technology .
Technical Highlights: Why This Painting Robot Excels
Beyond cost savings, the P1500-B-6 painting robot stood out for its technical capabilities:
1. Constant Arc Length Control: This feature maintained optimal gun-to-part distance, ensuring even layers on curved or irregular surfaces.
2. Multi-Material Compatibility: The robot handled everything from solvent-based paints to waterborne coatings, adapting to environmental regulations .
3. Data Connectivity: Integration with the factory’s IoT platform allowed real-time monitoring of paint consumption and predictive maintenance.
For the client, these features meant long-term reliability and adaptability to future product changes.
Broader Implications for Manufacturers
This case study reflects a broader shift toward robotic painting automation in industry. Key takeaways include:
- Rapid ROI: Most businesses recover their investment in 12–18 months through labor and material savings .
- Sustainability Benefits: Reduced overspray and VOC emissions support corporate green initiatives .
- Competitive Advantage: Consistent quality helps secure contracts with demanding clients like automotive OEMs.
As one automotive supplier noted, “Automation isn’t just about replacing people; it’s about enabling growth without compromising on quality” .
Conclusion: Is the Painting Robot a Right Choice for Your Business?
This case study demonstrates that a painting robot can deliver substantial financial returns while addressing operational inefficiencies. For companies struggling with high waste, variable quality, or rising labor costs, robotic painting automation offers a proven path to competitiveness.
At SZGH, we specialize in tailoring solutions to specific needs. Our P1500-B-6 painting robot is part of a broader range of industrial robots designed for painting, assembly, and material handling. Whether you’re a small workshop or a large factory, our team can provide a detailed ROI analysis to guide your decision.
Ready to explore your savings potential? For a free consultation and discover how a painting robot can transform your operations.
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