Refinisher Vol61 Issue 4 2019

THE V O L U M E 6 1 • I S S U E 4 D E C E M B E R 2 0 19

Harley-Davidson’s

electrifying future ALSO INSIDE: DON'T LET YOUR STAFF HOLD YOU HOSTAGE

INSIDE THIS ISSUE

• PPG’S DIGITAL ECO-SYSTEM • 2 019 PPG COLOUR MATCHING COMPETITION • QUALIT Y ON A TR AY

PPG Australia McNaughton Road Clayton, VIC, 3168, Australia 13 24 24

PPG New Zealand 5 Vestey Drive Mount Wellington, 1060 Auckland, New Zealand 0800 320 320

contents DECEMBER2019

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SCA N TO RE A D T HE REFINISHER ONLINE

61 VOLUME

THE

REFINISHER

ISSUE 4

Editor-In-Chief Paul Galea

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Editorial Co-ordinator Kevin Woolerton

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News

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Architects of the future

Editor John M Stanley Creative Director Dean Parrott

Developing a very cool collision repair workplace

Published for and on behalf of PPG Industries Pty Limited by

Kisschasey Creative Pty Ltd Unit 113, 91 Murphy St. Richmond, Victoria, 3121 Telephone (03) 9421 3311

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16

50 years of specialist skills and knowledge

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20

Victoria 104-106 Woodlands Drive, Braeside, 3195 Telephone (03) 8586 0000

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New South Wales 10 Peter Brock Drive, Eastern Creek, 2766 Telephone (02) 9854 6600

Tasmania PO Box 406, Kings Meadows, 7249 Telephone 0412 254 807 Western Australia Unit 2/6 Colin Jamieson Drive, Welshpool, 6106 Telephone (08) 9256 3920

PPG Logo, Delfleet, Deltron, Envirobase, Global Refinish System, Harlequin, PaintManager, Prizmatique, Radiance, RapidMatch, Startline and ‑ are registered trademarks and We protect and beautify the world, Crystallance and RapidMatch are trademarks of PPG Industries Ohio, Inc. SATA and SATAjet are registered trademarks of SATA GmbH & Co. KG. Third-party trademarks referenced in this magazine are the property of their respective owners.

Don’t let your staff hold you hostage Take the lead on products and processes

Queensland 18 Breene Place, Morningside, 4170 Telephone (07) 3823 8000 South Australia 97-105 Bedford Street, Gillman, 5013 Telephone (08) 8346 6870

Plug and play An all-electric Harley-Davidson may sound a little bizarre but it fits perfectly with the company’s original ethos. Heading into a low-carbon future, the LiveWire™ model is a next-gen way of giving customers exactly what they want – personal freedom!

Australia Head Office Locked Bag 888, Clayton South, Victoria 3169.

McNaughton Road, Clayton, Victoria, Australia, 3168 Telephone: 13 24 24 www.ppgrefinish.com.au New Zealand Head Office 5 Vestey Drive, Mt Wellington, Auckland, New Zealand.

Toll Free Telephone: 0800 320 320

Established heavy hitter

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Spreading Green Belt Green Belt training is going direct to repairers

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Heavenly bodies The rise and rise of Triple M Truck Bodies

NEWS REFINISHER

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PA IN T RE C TI FI C AT IO N

PR O C ES S

SMALL AREAS SMA LL AREAS

Updated ‘Paint Rectification Process’ chart D

eveloped by the local PPG team, the Paint Rectification Process chart has provided efficient de-nibbing and polishing methods to help minimise job labour cost. Now this handy guide has been updated with the latest products and techniques. The A3 size chart is designed to display where staff can easily refer to it. Rather than ‘one size fits all’, it lets the user choose options that keep each job as small and fast as possible. It’s free and getting a copy is as simple ask your MIRKA distributor or a PPG Territory Manager (including Protec and Commercial SCA N TO RE A D T HE Performance Coatings). R PROCESS CH A RT

1 2

Action: Sand dirt nib.

Use: Machine and grit SR7 then SR5 disc

Action: Compound sanded area.

Use: Polarshine 35 & 85mm Yellow Wool Pad

3 Action: Compound sanded area.

Use: Polarshine 35 & 85mm Yellow Waffle Pad

4

Action: Sand defects.

Use: Use grit P1200 or

2 P1500.

Action: Final sand.

Use: Abralon grit 3000.

For best results use

3

Action: Compoun d sanded area.

Use: Polarshine 35 and Lambswool 150mm pad.

4

Action: Compoun d sanded area.

Use: Polarshine 15 and Yellow Waffle 150mm pad.

5

Action: Polish compound ed surrounding area.

isitors to the high octane Summernats festival in January 2020, won’t have any problem locating the PPG stand. It’s on PPG Corner and it’s one of the biggest marquees on site at 25 metres by 20 metres! Along with some very cool cars, it will be packed with PPG colours. A series of PPG ‘Masters of Custom’ style panels will show the step-bystep process of creating an epic paint job – from prepped bare metal, to final finish – featuring PPG’s VIBRANCE COLLECTION® primers, colours and finishes and specialised clearcoat. Another fan favourite is the ‘Retro Colour Wall’, featuring a series of classic muscle car colours from Ford, Holden, Chrysler, etc. And, whether you are a refinish professional, a custom painter or just planning your dream build, the Summernats is a fantastic opportunity to chat with a PPG expert. R

a Mirka RPS variable

Action: Waxed polished Use: Polarshine Liquid area.

Nano wax with microfibre cloth.

For best resuts use

PRODUCTS

speed polisher

6

Use: Polarshine 5 and Black Dotted 150mm pad.

Note: For use on dark colours.

a variable speed polisher.

COMPIFICA RECT OUND S/POL TION ISHES PROD /WAXES UCTS ABRASIVE PRODUCTS

POLARSHINE 35

POLARSHINE 15

250ML / 1L

1L

7992800251 / 7992810

111

7994015111

POLARSHINE 5

POLARSHINE LIQUID WAX

1L 7990500111

PADS

NANO

1L

ABRALON P3000 x 150mm

7992725111

P3000 x 77mm

8A24102098

8A20302098

POLARSTAR SR5 P3000 x 32mm

100 / 500

FS30009905 / FS30000

105

SR7 P2500 x 32 mm

BACKING PAD 32MM 8294593311 / 8294596 311

LAMBSWOOL PAD 150mm 7994015111

AUXILIARY

107

PRO-SERIES PUMP

YELLOW WAFFL

80mm

150 x 25mm

7990082111

7993415021

E

85 x 25mm 7993408521

BLACK WAFFLE 150 x 25mm 7993115021

85 x 25mm 7993108521

ACCESSORIES BOTTLE

STA.001PS01

MICROFIBRE CLOTH STA.01160/UNIT

FINESSING DAMPER

9190101001

60ml

SHARK BLADE 48x28m

m

7872000111

ROS150NV 32mm 8992450111

SANDERS ROTARY SANDER

& POLISH

8992340111

650CV 150mm 5.0 MID6502022AN

100 / 500

FS30009907 / FS30000

BACKING PAD 135 X M14 829790211

PPG goes big at Summernats V

Action: Wax polished area.

Use: Polarshine Liquid Nano wax with Startline Microfib re Cloth.

colours

LARGE AREAS

1

5

Action: Polish compou nded surrounding area Use: Polarshine 5 & Black Waffle 85mm pad

Note: For use on dark

325CV 77mm 2.5 MID3252011AN

NEWS 5

REFINISHER

DRIVETHROUGH

Revamped training centre host V8 Drivers Night Q

uestion – Where do you get to hang out with 13 driving stars from the V8 Supercars series in one spot? Answer – The PPG V8 Drivers Night at PPG New Zealand’s refinish headquarters at 5 Vestey Drive, Auckland! Held on Thursday evening before the Pukekohe round, this hugely popular event saw around 140 customers rubbing shoulders with their Supercars heroes. This year, it was also the perfect opportunity to check out the totally

revamped Auckland Training Centre, complete with new booth, double prep bay, tint / mixing room and other state-of-the-art equipment. With the drivers mingling with the crowd, having photos taken and participating in Q&A session, it was the beginning of an epic weekend!

For more information on PPG training courses or to book a course, speak to your Territory Manager, your Training Manager R or call (NZ) 0800 477 487.

PPG extends NHL partnership P PG will continue its partnership as ‘Official Paint’ of the National Hockey League (NHL®) in the U.S. and Canada for a further three years. Not only that, colourchanging thermochromic coated pucks will officially be used in all NHL games during the 2019 / 2020 season. This advanced coating was developed closely with PPG suppliers LCR Hallcrest and QCR Solutions Corporation to solve an age-old problem.

An ice hockey puck glides faster and more smoothly when frozen but, as its temperature rises, it needs to be replaced.

By changing from purple to clear when a puck’s temperature is above freezing, the specialised coatings gives officials a visual indication that the puck should be replaced. R

with Paul Galea

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ou may not be familiar with the term ‘digital eco-system’ but, for collision repairers, it’s something well worth getting excited about. Our article on page six gives an insight into how PPG’s Digital Customer Experience team are using it to shape the future of digital interactions across the collision repair process.

In fact, the development program has actually been going on behind the scenes for some time.

For a clear example, look no further than the RapidMatch® GO spectro which smoothly works with the PaintManager XI® software and all its super complex algorithms, to help repairers get a fast and accurate colour match. In 2020 we will see the next wave when the very cool, MoonWalk® automated mixing system arrives locally. Ultimately, we believe our digital eco-system has the potential to transform the way the collision repair sector is viewed from the inside and outside.

With more and more interconnected digital systems in the future, collision repair won’t just be more efficient, it will also be a very cool, tech-enhanced place where people will want to work.

I would also like to give a shout out to our finalists at the 2019 PPG International Colour Matching Competition (pg 30), as well as everyone who participated throughout the year. Feedback has been that it was another great event, with a very positive group of apprentices who were enthusiastic about improving their colour matching skills.

With young people, such as these, set to play their part, the future of the industry R looks a lot brighter!

DIGITAL CUSTOMER EXPERIENCE REFINISHER

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Architects of the future What will the collision centre of the future be like?

If Beppe Casalini and his PPG team has its way, it will be a very cool place to work, packed with connected, high-tech solutions.

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ake a look around your current collision centre workplace and have a guess at some of the innovations that might appear in the next five, ten or, even, twenty years. Let your mind run to the wildest, ‘out there’ ideas you can think of.

How about drone deliveries of parts and consumables, automatic scanning and estimating of accident damage or, perhaps, onsite 3D printed parts. Whatever you come up with, chances are PPG’s global refinish Digital Customer Experience team has already considered it and, in many cases, is on the way to making it happen.

Does all this sound too farfetched?

Go back 20 years or so and consider how painters felt when PPG introduced the first portable, mass-market spectrophotometer.

Paired with PPG PaintManager® software, it was a breakthrough technology that brought incredible speed and accuracy to the colour matching process. After joining

PPG in 1995, it was Beppe Casalini, along with his team, who were responsible for these innovations, as well as the further enhancements that have come with the latest PaintManager XI® and RapidMatch® GO tools. Today, Beppe operates from PPG Italy Business Support Srl, in Milan, and is responsible for what is called the ‘digital customer experience’ that PPG refinish offers. We caught up with him recently when he visited Melbourne.

Digital customer experience We all seem to have embraced the technology revolution in our everyday life (think smart phones, WiFi connectivity, tablet computers, streaming your favourite programs, etc.), so Beppe’s Digital Customer Experience team says, why not make use of it in the collision centre?

“The Digital Customer Experience is a global PPG function that was created to answer the demand to be more digitally oriented in the refinish sector. As a main goal, we look after all the customer facing software applications. In parallel with developing new technology, such as MoonWalk®, we are also gathering requirements for what we call the new ‘digital eco-system’ that PPG is in the process of preparing for customers.

The concept of a digital eco-system is to create an immersive experience for

DIGITAL CUSTOMER EXPERIENCE 7

customers. It’s about building an overall solution for customers which is more tailored and easier to be used. The key drivers for our work are to avoid waste and save time which helps make a shop more profitable.”

The power of many Rather than go to customers with what they believed were the solutions to improve profitability, Beppe’s team actually asked for input from customers, as well as distributors

and PPG internal staff. Given PPG’s vast footprint in refinish markets right around the globe, this involved feedback from literally thousands of collision repairers.

“In Europe, more than four years ago, we started a kind of customer-centric approach to discovering problems they had in doing their day-to-day jobs. From this, we could look for technologies to release those pains.

The biggest source of ideas is found with talking to people – PPG staff, customers

and distributors. For example, this is the fourth week in a row where I am travelling around the world running workshops where we talk to our people and ask what they think we need to build for the future.

Very often, we forget that technology already exists in our life, however it may be at home but not at work. We get people to think about these various technologies and how they might be used to make life easier for our customers or within PPG.” “We listen to everybody’s opinions and ideas – when you sit down with people who

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DIGITAL CUSTOMER EXPERIENCE REFINISHER

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Architects of the future

Positive image maker

really want to innovate, there is so many creative things to work with.

There is a whole spectrum of ideas – from straightforward requirements to the more ‘crazy’ ideas. Even if 30% of the ideas are not possible because the technology doesn’t enable it today, that means the other 70% can still be put in the mix to create the disruptive features for PPG’s digital eco-system and that is pretty impressive.”

MoonWalk leads the way While Beppe’s team has already put the runs on the board with the powerful and intuitive PaintManager XI software and easy to use RapidMatch GO spectro, it’s the spectacular new MoonWalk automated mixing system which is grabbing the latest headlines. As well as effectively reducing waste in multiple areas (in product, in labour time and in productivity), MoonWalk also frees up painters to do what they are trained for – painting!

“We appreciate that mixing paint is an extremely important task but what MoonWalk does is remove this non-valueadded activity from the painter to release pressure on them. I’m certain it will help them focus on more productive activities.

With MoonWalk becoming a colour identification and dispensing station, the

shop can have a less skilled person taking care of it. Precision is the key to getting the correct colour mixed in the exact volume but that is not easy when a tinter must be added in a tiny volume. Being extremely precise over a long and busy workday is not easy. Say you add a drop too much of a tinter. If you are very diligent, you will recalculate to mix a larger volume – which is more wastage – but some people might also be tempted to take a shortcut and that could end up as an inaccurate colour match.

The MoonWalk project started with analysing this problem and then coming up with an effective technical solution to solve it.”

Whilst interviewing customers during the MoonWalk project, Beppe says the team stumbled onto a very positive side effect.

“We asked customers, ‘do you like your job’ and the answer was generally, yes.

Then we asked, would you recommend your children did the same job – they said, no, they don’t want to work in this environment because it’s messy. Therefore, the concept of MoonWalk is not only to save time and convert it into profit, it’s also to keep the work environment cleaner and more professional. In fact, we believe MoonWalk will be a talent retention or talent enabler tool. It’s simple and effective but people also like the way it looks and feels. When we first showed the prototype to customers, we told them we had designed it to be small enough to install in almost any mixing room. It was a real eye-opener when they said, no, it’s too nice to be hidden in the mixing room.

They thought it looked so good, they wanted it in the front office where they could show it off to their customers.

They could even ask the car owner if they wanted to make their own colour!”

What’s next in the digital eco-system?

“PPG is looking to invest even more in the digital area and we have quite an interesting pipeline of new products. I have to keep a little bit quiet about the next big thing but it’s a platform of solutions which are all interconnected and it will be a much more immersive experience than the current arrangement. Because PPG refinish is such a global organisation, we are able to make an impact with a wide audience right across R the world. That is really rewarding!”

PPG ARCHITECTURAL COLOUR 9

CH NIGHT WAT

Colourful effects Colour surrounds us but we tend to underestimate its impact. A recent Taubmans study has shown that colours can instinctively influence a whole range of emotions and moods.

F

or vehicle brands, colour is a key selling tool because it generates an emotional response – good, bad or indifferent. Colour can have a similar impact in our day-to-day life.

A WINTER SE Indeed, a study conducted by PPG’s well-known Australian architectural brand, Taubmans, in consultation with The Florey Institute of Neuroscience and Mental Health, workshop? Right now is the ideal time to scientifically proved that colour has the ability think about sprucing up the workplace with to bring out a whole range of emotional a fresh coat of paint. responses. It found that painting walls or The warmer weather and an entire room in certain colours can make longer daylight hours make for people feel relaxed and calm or, even, perfect painting conditions. cheerful and excited. On the flipside, other Indeed, getting it done over colours can risk making people feel bored, the traditional festive season sad, tense or, worse still, irritated. / New Year break could see Note: In New Zealand, PPG’s premium the year kick off with a fresh architectural products are sold under the look and feel to the PPG Paints brand. work environment that promotes a positive Colour for collision experience for staff We know how important colour is in the and customers, alike, refinish paint shop but have you ever according to Rachel HUSK GOLD stopped to consider the best colours to Lacy, Colour Category paint your collision centre reception area or Manager, PPG ANZ.

Reception area “Anchored in nature, green is a grounding colour that is well suited to reception areas. Green evokes a sense of comfort, calmness and security – just the kind of atmosphere you want to create for stressed out customers who have experienced a collision or other mishap with a vehicle.

A verdant hue like ‘Night Watch’ is ideal for light-filled reception areas, as it helps to bring balance both aesthetically and emotionally, creating a cocooning effect.

For darker rooms, a lighter forest green like ‘Winter Sea’ or ‘Bayberry Green’ will work equally well to create a comforting, reassuring atmosphere.”

Workshop “An energising yellow, like ‘Husk Gold’, can help to support a productive and lively workshop environment.

Yellow brightens a space, so it is best used on a south facing wall or room.”

Endure interior paint range As well as being asthma and allergy friendly, the Taubmans by PPG Endure range delivers superior 8-in-1 multi-benefit protection that helps to keep surfaces clean, healthy and fresh looking, year after year. Anti-microbial properties mean that, once dry, the paint actually inhibits the future growth of mould R and mildew.

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BAYBERRY GR

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FEATURE PANEL SHOP REFINISHER

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E M U P L A I N S S M A S H R E PA I R S

Established W heavy hitter Backed by 50 years in operation, Emu Plains Smash Repairs is utilising its specialist skills, knowledge and equipment to carve out a healthy niche for itself.

hat does it take for a collision repair business to successfully navigate its way through five decades in an increasingly volatile industry?

For Emu Plains Smash Repairs, it has taken a combination of factors. While much has remained the same over the years, such as the passion and drive of the Hawks family and the location, other things have been constantly upgraded, including equipment, technology and skills. When Phil and Noelene Hawks opened the business back in 1969, the suburb of Emu Plains was very much on the outer fringes of Sydney’s west but customers were happy to travel there for the quality of work they received.

Darren Hawks says he joined the business in 1989, where he completed a spray painting apprenticeship and served another five years as a tradesman before Phil really began showing him the ropes.

“Dad taught me how to quote and how to run the business and it got to the point where we just ran the business together.

One week he might do quotes and I would look after the workshop or vice versa.

It wasn’t like I was just thrown in the deep end when dad retired – I knew how to run the business. Having said that, times have changed with workloads and it’s so much more hectic and fast-paced. Back then we only had about eight staff – now we have 23!”

Phil remained part of the business into the 2000s but his health declined and, unfortunately, he passed away in 2007.

Today, Noelene remains an owner and involved in the business but it’s Darren and his wife, Amanda, who have taken the day-to-day reins – Darren in the workshop and Amanda on the admin side. Although the business effectively started off in a tin shed with an ash floor, a regular series of extensions and upgrades to equipment have been crucial to keeping it modern, says Darren.

FEATURE PANEL SHOP 11

“You have to keep up with technology or you get left behind. For example, about three years ago we installed two new Low Bake spray booths. One is a conventional oven, while the other is fitted with gas-infrared, like at PPG’s NSW Training Centre. It’s awesome and, together, it gives us the best of both worlds. The gas-infrared may not be cheap to install but it’s cheaper and easier to run than a conventional booth and it’s great for smaller stuff because it’s so quick.”

Around this time, the focus also went onto the paint brand the business would use going forward. When an awkward colour had cropped up, PPG’s ability to quickly help with matching it got Darren thinking.

“It was time for a change so I looked at all the waterborne paint brands and did shop trials and demonstrations. I just found PPG’s Envirobase (High Performance) easier to use

and the painters love it. We bit the bullet and changed the booths and the paint system at the same time.

It was a steep learning curve but it was worth it. I was told you won’t fault PPG’s aftersales service and that is what I have found. If I call PPG with an issue, they are straight here.”

While Emu Plains Smash Repairs does its fair share of regular accident repair work, it has also managed to retain a point-ofdifference by gearing itself to a steady stream of larger, structural type repairs.

“Many years ago, we ran tow trucks so we have always been involved in structural repairs. Today, tow-in work is a big part of our business – at any one time we have at least 30 tow-in jobs onsite. Around this area there is not a lot of repairers who want to touch structural stuff. Some don’t have the staff and some don’t have the equipment

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FEATURE PANEL SHOP 12

Established heavy hitter

REFINISHER

E M U P L A I N S S M A S H R E PA I R S

but we have both. Along with a couple of Car-o-liners, we have 3D measuring equipment and the appropriate spot welders.

I even get insurance companies sending vehicles here just to be digitally measured. It might get repaired elsewhere but we get asked to, say, 3D measure the chassis to make sure it’s right. We are taking dashes and engines out all the time and, these days, we have a mechanic on staff who does a lot of those things, as well as suspension damage.”

“Like everyone else, it’s hard for us to find good skilled staff, particularly because I need panel beaters who can do structural repairs. A lot of younger tradespeople struggle with that type of work. That is why we employ apprentices and do a lot of I-CAR training. Currently, we are on our way to ‘I-CAR Gold’ and I’m actually ‘I-CAR Platinum’. Paint training is through PPG – Terry Noble (PPG Business Support Specialist) will do training here or our staff will go to PPG’s NSW Training Centre.

Our third-year apprentice painter, Teeghan Shackley, has become a great part of our paint shop team. She has a really good work ethic and she does everything to the best of her abilities which has helped grow a really good bond with the male tradesmen she works alongside.”

S H O P FA C T S Emu Plains Smash Repairs Owners: Noelene and Darren Hawks Staff: 23 PPG Product: Envirobase High Performance Territory Manager: Phil Taylor

While the industry has seen plenty of changes in the 50 years since Emu Plains Smash Repairs started, Darren reckons the next five to ten years will see even more challenges. Just as it was in the past, Darren says meeting those challenges is about having the right equipment and skillset in place.

“I remember when airbags first came out – it was a big thing and people were concerned about replacing them.

Now we do them every day of the week and something that was daunting 25 years ago, is now run of the mill. It’s all about learning the right repair processes and following instructions.”

As part of his partnership with PPG, Darren has taken advantage of the MVP Business Solutions program by going to courses and seminars, as well as having one-on-one onsite sessions.

“I think the MVP Business Solutions sessions are really valuable to attend. It’s easy to get caught up in your own little world so it’s good to be able to network with other repairers.

It’s particularly good to be able to float ideas and hear how other business owners do things. It could be anything in the shop – repair methods, dealing with staff, how to set up for the best performance, etc – and you might think you have the best process until you hear how someone else does it.”

Although it has not always been easy, Emu Plains Smash Repairs has always managed to maintain good insurance company relationships.

“Over the years, we have always been recommended repairers for insurance companies, including today where we are recommended by the big two, as well as a few of the smaller ones. People will whinge about insurance companies but, at the end of the day, we need them as much as they need us. I like to think that we are in a good position because we are set up to do larger structural repairs. While it would be nice to have a nice new factory, managing the business the way we are and doing the R work we are is suiting us fine.”

THE SCIENCE BEHIND 13

For the typical polyurethane refinish product, the hardener is an isocyanate and the chemistry is the same, regardless if it’s a primer, a colour coat or a clearcoat.

The cross-linking reaction happens quite slowly at ambient temperatures, therefore giving enough time for the paint to be applied before baking accelerates the chemical reaction to fully cured. Paint chemists refer to ‘cross-link density’ and the higher it is, the more rigid and robust it is, although taking it to the extreme will make it brittle. PPG’s ground-breaking CeramiClear® mar and scratch resistant clearcoat is a good example of a product that is supertough thanks to its high cross-link density.

OEM vs refinish

Watching paint dry We are told that it’s boring to watch paint dry but, when it comes to the automotive sector, the science behind it can actually be quite interesting.

Y

ou may not need to know what is going on inside that paint you use every day but it’s still a fascinating subject, says Refinish Marketing Director ANZ, Kevin Woolerton.

around each other. If you evaporate all the water and dry it, you get a solid – this is the basic concept of a 1K or one-pack paint product.

For a two-pack product, we take that bowl of spaghetti and add another ingredient, the hardener, which causes cross-links to be formed between the polymer strands, like the rungs on a ladder.

The difference between OEM vehicle finishes and their refinish counterparts, largely comes down to temperature. In the OEM world, the paint chemistry is designed to react and cross-link at high bake temperatures (typically, 120°C to 130°C) without using a hardener. This is fine on an OEM production line because they are working with a bare bodyshell with nothing attached. In contrast, taking a car off the street and baking it in a booth at 120°C to 130°C would see the plastics melted on the floor, the electronics fried, etc. This is where isocyanate hardener comes in. In a refinish situation, it allows you to get the same degree of cross-link and durability, etc. after being cured at typical spray booth bake temperatures which are around half of those used by OEMs. R

A bowl of spaghetti We paint chemists talk about paint being made up of a polymer or resin which is the same thing. Drill down to the molecular level and it’s essentially made up of long strands of carbon atoms with other atoms and compounds attached, depending on the type of paint it is. Imagine these long strands as a bowl of spaghetti – it’s not a liquid but it will flow and the strands can twist and coil

OEM

Refinish

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SATA REFINISHER

14

Covered in classic paisley motifs and flower power art, the SATAjet X 5500 ‘Hippie’ special edition encourages you to spray with love and peace.

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hey say that the legendary Woodstock Music Festival was such an epic party event, if you can remember it, you weren’t there! Held over three days in August 1969, it marked a pivotal time in world history as young people chose to reject the cold war’s threat of nuclear Armageddon and embrace peace, love, music and harmony with nature.

In order to commemorate the 50th Anniversary of the Woodstock Music Festival, SATA has created a special edition spray gun, dubbed ‘Hippie’, which recognises the cultural impact of the era.

The SATAjet X 5500 Hippie takes its cues from the classic images of that period back in 1969, when ‘peace, love and music’ was the motto of the ‘summer of love’ and was highlighted by hippies decorated with flowers, bright multi-coloured Volkswagen Beetles and Kombis, peace symbols, etc.

These colourful motifs and more have been reproduced as a unique, high quality surface coating finish. Like previous SATA special editions, the ‘Hippie’ is a fully functional spray gun and suitable for daily use in the spray booth. Alternatively, it also makes an excellent collector’s item to go into a display cabinet.

Best of all, this very cool special edition spray gun is based on SATA’s latest premium model, the SATAjet X 5500.

Therefore, it’s available in all the current nozzle sizes, along with the choice of HVLP

and RP technology and in non-digital and DIGITAL® format. Naturally, being a special edition means this is a time-limited promotion available from your SATA distributor only while stocks last. Reserve your SATAjet X 5500 Hippie now to avoid disappointment.

SATAjet X 5500 key features

• Revolutionary SATA X-Nozzle System takes atomisation to the next level • Consistent: Uniform fan size across the entire nozzle range with linear increments of the material flow rate • Versatile: Two fan shapes for each nozzle size helps meet every application requirement • Precise: Optimised material distribution for a more uniform and enhanced atomisation • Efficient: Substantial material savings under the same application conditions • Individual: Capable of matching any application requirement, including for paint material, climatic conditions or the paint’s technique.

CONSUMABLES SOLUTIONS 15

Nothing is as good as Thanks to a new multi-hole configuration, MIRKA’s popular Gold abrasives range offers an ideal solution for the modern sanding process.

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he MIRKA Gold range is already the most popular paper-backed abrasive in the company’s portfolio but that didn’t stop its R&D team from giving it a major upgrade to further boost performance. Drawing on feedback from existing customers, along with intensive research, the new Gold range features a variety of improvements headlined by new computer designed, multi-hole patterns – Gold 150 mm (6”) discs are now available with the new patterns which have 37 holes for coarser grits and 121 holes for finer grits.

Building on Gold’s reputation for all-round versatility, efficiency and

Belts for the daily grind When it comes to belts for your Dynabrade style tool, here is a new option you can rely on for long lasting, cost effective performance.

I

n today’s process driven industry, the PPG team is looking to search out and source dependable, convenient alternatives for the panel repair sector, as well as the paint shop.

It’s all about offering solutions that will fit perfectly into the local market, says says Kurt Way, PPG Category Manager, Associated Products.

“As part of a move to new, more streamlined processes, we have been looking at new tools and new abrasives with the ultimate aim of offering a complete endto-end repair method and these new belts fall nicely into that category. These are hard

Gold

quality of finish, the new multi-hole patterns were specifically created to take dust extraction to the next level. Compared to traditional paper abrasives and other multi-hole patterns on the market, the superior dust extraction capabilities of Gold directly translate into improved productivity, a longer lifespan and a cleaner workshop. Reducing clogging on the abrasive surface increases speed of cut and durability, while also makes it easier for the operator to see the surface which improves the quality of finish.

Best of all, this new MIRKA Gold abrasive works perfectly in conjunction with the outstanding MIRKA power tools range. R

wearing, high performance abrasive belts that are designed to fit both Dynabrade tools and other makes of similar tools.

They come in standard sizes (330mm X 10mm and 520mm X 19mm) and in the most popular abrasive grades (P40, P60 and P80) and are specifically designed to use on metals and composites, as well as timbers. In the average panel shop, they are perfect for grinding smaller spot welds, right through to thicker welds. Importantly, you get strong, reliable, long lasting performance R at a very reasonable price.”

Available from PPG associated distributors and PPG Paint Powerhouse stores.

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FEATURE STORY REFINISHER

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B

ack in 1903, as William S Harley and childhood friend, Arthur Davidson, put the finishing touches to the very first Harley-Davidson, it’s doubtful they could have foreseen its true significance. Although it was little more than a strengthened bicycle frame with an internal combustion engine attached, it gave people what they craved – personal freedom.

This was enhanced when the first of the company’s seminal V-twin powered models hit the market in 1909 – an engine configuration which has been a core feature ever since.

While that is not about to change any time soon, Harley-Davidson is once again determined to lead the charge as the motorcycle industry makes the seismic shift to electrification. By offering the traditional premium look and feel of a Harley-Davidson, combined with a high performance motorcycling experience that embraces new levels of technology, the all-electric ‘LiveWire’ is set to introduce a whole new generation of riders to the brand. It’s very much a 21st Century machine and undeniably a ‘Harley’. And, for a company that has become famous for chrome, style and that signature V-twin rumble, it’s an incredibly bold move that harks right back to the pioneering spirit which first set the company on the path to being one of the most iconic brands in the world.

Just as it did more than a century ago, Harley-Davidson has taken a leap of faith as its next-gen LiveWire™ model gets set to lead the motorcycle industry into an all new era.

FEATURE STORY 17

Electric power point A glance at any past or present Harley-Davidson makes it obvious that the motor is designed to be a key, eye-catching element and LiveWire is no different. Taking center stage is the bright casing and muscular shape of the H-D Revelation™ permanent magnet electric motor which is positioned longitudinally and low in the chassis for a lower center of gravity. Mounted directly above, the cast aluminum case for the high-voltage lithium-ion battery features highly styled and functional cooling fins.

And when it comes to performance, this next-gen Harley-Davidson delivers a true electric shock. Because there is no traditional transmission and no clutch, riding the LiveWire is an incredibly userfriendly and thrilling ‘twist and go’ proposition. Unlike an internal combustion engine, the H-D Revelation motor can produce 100% of its 110Nm (81ft.lb) of rated torque from the instant the throttle is cracked open and, because maximum torque is always on tap, roll-on acceleration once on the move is outstanding.

The result is smooth, seamless, incredible acceleration from any speed. We are talking 0 to 100km/h in just three seconds and 100 to 129km/h in a sizzling 1.9 seconds!

With a 15.5kWh capacity, a fully charged battery provides 235km (146 miles) of city range or 152km (95 miles) of combined stop-and-go and highway range. Using DC Fast Charge technology, it’s capable of taking the battery from 0 to 80% charge in 40 minutes or 0 to 100% charge in 60 minutes. While riding, there is also a programmable power regeneration system where the motor becomes a generator to flow charge back into the battery when coasting ‘off throttle’ or when using the engine braking effect.

Electrifying color Color is considered to be a crucial element of every Harley-Davidson but what is the right color for this landmark new electric motorcycle?

According to Harley-Davidson, the paint treatment had to reflect the advanced technology of the LiveWire and, for a solution, it turned to its long-term partnership with PPG which began back in 1989.

Laura Nelson (PPG Liquid Industrial Coatings ACDC Technical Manager) and her diverse and talented team are responsible for supporting Harley-Davidson from color development through to production line application. Creating colors for LiveWire formed part of the annual color program, Laura explains.

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FEATURE STORY REFINISHER

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“Color is one of the features that sets Harley-Davidson apart from the competition. To them, it’s not what a color looks like but how it makes you feel. For an electric bike, you need electric colors with excitement, energy and ‘pop’.”

As a result, LiveWire buyers can choose from two exclusive colors – Yellow Fuse and Orange Fuse – as well as long running favorite, Vivid Black, which was also created in conjunction with the PPG team. In fact, for each model year PPG and Harley-Davidson develop around 40 to 50 ‘color spaces’.

Of these, about 30 will make it to the showroom floor, says Laura.

“The color development process is very thorough. First, HarleyDavidson reviews their assessment of future market trends and combines that with information from PPG's Global Color Show.

Harley-Davidson stylists will then provide verbal color direction of what they are seeking for the new model year. Here at the PPG support team, it’s up to us to translate those verbal color directions into what we refer to as color spaces. From there, Harley-Davidson and PPG work together to refine the color spaces during a yearly workshop. After that, the color spaces are defined and transferred

to PPG's Oak Creek, Wisconsin facility.

There, the color spaces are transformed into materials Harley-Davidson can use in their production facilities.”

As well as the vast experience it offers, Laura says the key to the success of the PPG team is diversity, teamwork and trust.

“When faced with an issue, we discuss it as a team and work as a team. The various experience levels and backgrounds within the team allows for some very interesting problem resolutions.

And that trust in not only amongst the PPG team, it’s also with Harley-Davidson. When Harley-Davidson presents a challenge to PPG, it trusts that PPG will champion the challenge and provide a suitable resolution.”

Wired for sound While LiveWire doesn’t have Harley-Davidson’s famous rumbling V-twin engine note, its arrival as a cutting-edge technology means it introduces its own signature sound which is actually derived from its drive components. A gearset is used to turn the H-D Revelation motor’s output by 90 degrees to align the drivebelt sprocket and the rear wheel.

As the LiveWire motorcycle accelerates and gains speed, the gearset has been specifically designed to produce a new Harley-Davidson sound which represents the smooth, electric power on tap.

Harley-Davidson engineers even added a heartbeat! When the rider activates the LiveWire powertrain, the electric motor produces

FEATURE STORY 19

a subtle pulse of torque – a ‘heartbeat sensation’ – designed to let them know that the bike has come to life and is ready to ride.

The pulsing stops once the bike starts to move and resumes when it comes to a stop.

Fully connected Along with a full suite of electronic rider aids, LiveWire includes an interface designed to allow the owner to create a personalized and full-connected riding experience. A 4.3-inch color TFT touchscreen is located above the handlebars to provide the rider with a range of information in a high-quality display that is bright and easy to read.

As well as being tilt adjustable to get the optimal viewing angle, the screen also adjusts for brightness automatically. It functions as a touchscreen only while the bike is stationary but many of the display options can be changed by using the hand-controlled joystick whilst on the move. Speedo, range and high-voltage battery status (shown in percentage remaining) are constantly displayed but the screen can be customized with various rider selectable ‘widgets’, including: • A power meter which indicates how much of the available power is being used as the motorcycle is being ridden • Ride Mode indicator displays which of the seven selectable ‘Ride Modes’ is active • Charging status shows the time remaining to full change when the motorcycle is plugged into a charging system • Alert information and tell-tale warning lights, including turn signals, ABS active, Traction Control active and Check Engine / Battery Overheat • Active Bluetooth connection and available functions

LiveWire is even equipped with H-D™ Connect service technology that provides cellular connectivity which can link the owner with their motorcycle via their smart phone using the latest version of the free Harley-Davidson™ App (available from the iOS and Android app stores).

Altered state LiveWire will not appeal to everyone but, like every Harley-Davidson, it’s not meant to. What it does do is offer an all-new motorcycling experience which is entirely fitting given Harley-Davidson’s pivotal role in kickstarting the motorcycle sector. The company sees LiveWire’s tech and easily accessible performance as appealing to new riders, as well as offering a thrilling alternative for accomplished motorcyclists.

Thanks to its advance technology, LiveWire radically alters many of the sensations that have previously defined motorcycling.

The H-D Revelation powertrain delivers extreme power in a seamless rush, while the simplicity of operation allows the rider to focus more completely on the real thrill of motorcycling – the dynamic sensation of acceleration and motion. More than ever, LiveWire provides something Harley-Davidson motorcycles have continually excelled at since 1903 – personal freedom and exhilaration.

Colorful relationship Despite her 23 years of experience formulating and troubleshooting liquid industrial coatings, Laura Nelson admits she never gets tired of watching paint come to life.

“After six years of working closely with Harley-Davidson, I'm still overwhelmed by how its stylists are able to look at a color panel and imagine the design of the bike.

The blends of materials, shapes and colors make the bike become an experience rather than an object.

The use of color to create this experience is simply amazing.

Harley-Davidson is always pushing the envelope and looking for the next big ‘Wow’. They share what they are looking for with us and PPG makes it happen. I tell everyone it's like a puzzle. And I really like puzzles!”

Note: American spelling has been used at the request of Harley-Davidson.

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TALKING TRAINING REFINISHER

20

Don’t let your staff hold you

hostage

Who dictates what products and processes are used in your business? If it’s not you, it could literally be costing your bottom-line hundreds of thousands of dollars per year!

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pen the consumables cupboard in some collision centres and you will find as many as four different brands of abrasive and the same with polishes. In the paint shop you might find old technology clearcoat being used or even a number of different clearcoats, depending on the preference of the painter. While this might keep individual staff members happy, it can have a disastrous effect on business performance and, in this day and age, that is not sustainable, says John Hristias, Business Support Manager Asia / Pacific.

Break the shackles Good staff are important and we do want them to have input into the business but, in today’s challenging industry environment, it’s crucial for the owner to take the lead.

This means choosing a streamlined and standardised set of products and processes to get jobs done in the most efficient way.

Things like, using the right clearcoat, UV primer, spray guns and settings, the right sanding process and so on and so on across the entire production cycle.

One excellent example is clearcoat and we covered this in the Talking Training article, ‘What is your investment strategy?’, in the previous issue of The Refinisher.

Basically, it compared the overall cost of using cheap, old style technology versus the latest modern clearcoat technology.

With old technology clearcoat you are talking two to three coats with flash-off in between, followed by a long bake time. Modern clearcoats dramatically reduce these times, as well as delivering other advantages, and actually cost considerably less overall.

Another example is your priming system.

The old-fashioned way is to ‘batch prime’ everything in the afternoon. However, if you want to improve cycle-time you should be doing things like priming throughout the

TALKING TRAINING 21

Decision making Leave key product and process decisions up to staff and what suits them might not necessarily be what is best for the business.

Humans are often resistant to change so it’s likely they will end up using the same old (and often, inefficient!) processes and products. Industry suppliers, such as PPG, are working hard to constantly develop new technologies to help improve efficiency and reduce cycle-time, with the aim of increasing profitability on each job, but it’s up to the owner to implement them and ensure staff stick to them.

Explain the benefits Being really open and honest with staff is a great way to help avoid the potential for them to get upset when changes are made. Give the team some insight into the challenges the business is facing and explain that changes are genuinely needed in order to keep the doors open. For each and every job, you need to identify the best processes and products to get it through the shop the most efficiently and ensure you get correct payment for your hard work.

Point out that you need their support to help adopt these new products and processes and make them part of the culture of the business. Training can be ideal for getting staff enthusiastic BREAK THE

day, taking advantage of the latest primer technologies (including UV primer), using infrared drying and employing Wet-On-Wet mode on second hand parts to reduce sanding time.

Talking about sanding, that is another process where some repairers continue to work in the ‘efficiency dark ages’. If you are still using wet sanding (hard to believe but it is still happening!), stop right now and start using modern, high performance products, such as MIRKA abrasives. If you are worried about the finish quality, consider all the successful jobs which are already being done with modern dry sanding technologies.

All of these examples highlight the fact that using the wrong product technology can actually cost your business ‘big time’.

about changes and they get to upskill at the same time. For example, when exotic new vehicle colours arrive, PPG training can get them quickly up to speed with the best application processes and techniques, before they tackle a live job.

Understand and monitor Whether from a panel beating background, a paint background or non-trade background, the owner still needs to have a basic understanding of any processes being implemented and any products that are used. It’s vital to monitor what is happening on the workshop floor and reinforce the need to use the correct products and processes because this is going to drive gains in productivity and, hence, profitability.

For example, PPG Trainers or members of the MVP Business Solutions team are happy to come in and train your team on best practice processes, techniques and product technologies but, if the owner doesn’t follow up after they have left, all those potential savings can simply evaporate if staff decide not to follow them.

At the end of the day, if you are paying your top technicians the ‘big bucks’ and they are not using the products and processes that have been specified, it’s actually you that it’s costing R money!

SHACKLES

EXPLAIN THE BENEFITS

DECISION MAKING

UNDERSTAND AND MONITOR

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CT REFINISHER

22

United we stand

A business philosophy based on upskilling and team work is helping Brokers United not only give customers exactly what they want, it is exceeding their expectations!

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t just 33 years old, Kurt Brokers is already a ten-year veteran at the helm of Brokers United. In that time, he has set the foundations with the original site in Waitara, on the mid-west coast of New Zealand’s north island, and followed up by adding a Rotorua outlet in 2016 and, more recently, a site in Tauranga, on the east coast. However, his proudest achievement is actually in empowering the 40 staff across the three sites which has made a crucial contribution to the business’s success.

“After doing a spray painting apprenticeship I wanted to continue upskilling so I did a panel beating apprenticeship. I ended up as a team

leader in a shop but management were not interested in listening to any ideas and that was very frustrating. I learnt from that and now I definitely make sure all my employees have a voice, everyone gets heard and no idea is a bad idea.”

When Kurt decided to go out on his own, at 23 years old, he started in a rundown building, with basic equipment and two staff.

After starting out doing a mix of cars and trucks, the workflow slowly shifted to mostly truck work thanks to the excellent reputation the business was generating. Kurt installed new equipment, including a truck booth, at the Waitara site but also went looking for opportunities to add more strings to the company’s bow, with the Rotorua and Tauranga sites subsequently introducing services, such as sandblasting and

painting structural steel. The next big move was a change of name.

“Brokers Panel & Paint didn’t really describe what we did anymore.

We wanted something that encompassed who we are as a business and as a group of people – we are a big family. These days, we do minor and major collision repairs, fibreglass repairs, plastic welding, refinishing, sandblasting, industrial painting and protective coatings. However, rather than

CT 23

going to customers and saying this is what we do, we asked them, ‘what do you need us to do for you?’.”

From the very beginning, Kurt says one of his strongest supporters has been PPG. Currently, Brokers United uses a full suite of PPG technologies, including the ENVIROBASE® High Performance waterborne basecoat system, the DELFLEET® Evolution paint system (specifically developed for CT applications) and products from the Commercial Performance Coatings range. While he appreciates the quality of these products, as well as now being a member of the PPG FleetPool network, it’s PPG people who have really cemented the partnership.

“It started with our PPG Territory Manager in the early days, Kurt Way – even though we were very small, he still gave us the same support as he would for a large paint user. Later, PPG CT Manager, Mark Brearley took me under his wing and spent a lot of time with me. Over the past five years, I have spent a lot of time with Helen Aird (MVP Business Solutions Manager NZ).

We have implemented lean management, including being part of the MVP Advance Lean Group, and worked on business development. I can honestly say my business would not be what it is without her. Like the other PPG people, her support is endless and she genuinely cares about improving her customers’ businesses.”

As he added new sites, Kurt has been sure to provide staff with any upskilling they need while also identifying the best practices and processes and spreading them across all three sites in order to

enhance the performance of the entire business. It’s all part of the teamwork philosophy.

“The vision of Brokers United is as one company utilising all our diverse expertise to exceed the customer’s expectation. I try to remove myself, as much as I can, from the day-to-day running. My big focus is on supporting my management staff and helping them do the best job they can.

Each shop has a Branch Manager and a Production Manager and we are all in close contact every day. I have empowered them to help each other and the Branch Managers do that every single day.

It’s very satisfying and humbling to watch.

I have played rugby my whole life and this business is like a big rugby team. We have measurable goals and we are all playing the same scoreboard. If we didn’t have a scoreboard, how would we know if we were winning or not?”

With youth on his side, Kurt says he is daring to dream big.

“The long term goal is to have a Brokers United outlet in every major centre in New Zealand. However, I am in no rush because I want to do things properly and make sure they all operate to a certain standard.

We already have nationwide customers and they want to know that they are going to get exactly the same high standard at each of our sites.” R

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MVP BUSINESS SOLUTIONS REFINISHER

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Spreading Green Belt A groundswell of interest from customers is seeing PPG’s MVP Business Solutions team deliver highly effective Green Belt Training direct to repairers across the region.

M V P – G R E E N B E LT

C O N T I N U O U S I M P R O V E M E N T P AT H W AY

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hen run in this region, the Green Belt Training program has been spectacularly successful in giving repairers the tools they need to make profound improvements to their business.

The only downside is that the course, itself, is typically run over a very intensive multi-day format which doesn’t suit everyone. As a result, the eight person MVP Business Solutions team has been delivering ‘bite-sized’ chunks of the program to a wide range of customers spread right across the region, says Greg Tunks, MVP Business Solutions Manager ANZ.

Continuous improvement pathway A full-blown Green Belt Training program is made up of a whole host of thought provoking topics, including strategic thinking, lean methodologies, measuring and reducing cycle-time, implementing change and much more. Essentially, what the MVP Business Solutions team has done is break Green Belt up into the individual presentations and make them available to any PPG customers who are interested. And there are plenty taking advantage! After all, why wouldn’t you want to reap the benefits?

Often, it’s driven by the fact that repairers are recognising they do need to make changes but they are not quite sure of the best way to do that. Aspects of Green Belt can also contribute points to I-CAR certifications. Another factor, is the influence of insurance companies who are looking for a certain level of performance from

the repairers they deal with. In today’s competitive marketplace, the proven way for repairers to get better is by taking a continuous improvement pathway and, when we look at Green Belt, it’s all about building in efficiencies and a culture of continuous improvement.

Our MVP Business Solutions team use components of Green Belt to work one-onone with our customers, day-in-day-out, but now we are also seeing formalised sessions being organised in various locations across the region to cater to a larger number at one time. If you are interested, you can talk to your PPG Territory Manager or simply drop us a line at the new, dedicated MVP Business Solutions email address mvp.anz@ppg.com. It’s a centralised contact point that anyone in the region can use and that enquiry will quickly be directed to the appropriate person to deal with it.

And remember, Green Belt Training is not just for light vehicle repairers, commercial transport repairers have just as much to gain from the program.

First step Every journey starts with a first step and, in the case of Green Belt, that is 5S methodologies. In basic terms, 5S lays the foundations that allow for continuous improvement. Unless you do step one, you can’t go onto steps two, three, four and so on. As the name suggests, it consists of five Ss to follow:

• Sort • Simplify • Systematic clean • Standardise • Sustain An organised workplace is a great place to work Apart from the boost to efficiency and profit, another upside of instigating 5S methodologies is that it makes for a happier and safer workplace for staff. If you are driving to work wondering what sort of crap you are going to face today, that indicates a dysfunctional workplace. Whereas, if you are heading to a cleaner, more organised workplace where thing are planned out, you know what is going to happen each day and it ditches the stress and heartache.

Which place would you rather work in? R

MVP BUSINESS SOLUTIONS 25

Systematic clean – This isn’t just about thoroughly cleaning the workshop (including equipment, etc), it’s about having a maintenance program in place for each piece of equipment to help avoid costly failures.

Sort – This is about sorting through everything to determine what is needed and what is really not needed. If something isn't used, get rid of it. If it gets used every day, make sure it’s close at hand and easily accessible. If it’s a piece of equipment that is not used regularly, store it away somewhere that everyone knows where to find it. If it’s something used all the time, make sure there is one at each workstation.

Sustain – This is by far the hardest point. Typically, people get excited at the beginning, get the whole team involved and make the previous four points happen.

However, once it’s all done, everyone tends to take a breather and that is when things start to slowly drift back to the old ways.

What it really needs is sustained pressure to ensure all these changes become the new culture in the business.

Simplify – This means to simplify systems, such as simplifying where we control all our stock, as well as having a place for everything and everything in its place.

Standardise – At this point we are talking about implementing a full set of standardised systems and processes. It sets in place the standard way things are done across the business which helps avoid individual staff doing things their own way while also guiding any new staff when they join.

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PPG PEOPLE REFINISHER

26

PPG Staff Profile

Andrew McCormick I t’s funny how life can turn on small moments. Andrew says he didn’t even know spray painting existed when he agreed to go on a TAFE pre-apprenticeship spray painting course with a mate. From there, he was hooked. “I finished the course, left school and started an apprenticeship at Parramatta Smash Repairs.

Over seven years it was a great place to work and learn.” Apart from using PPG products at Parramatta Smash Repairs, Andrew was impressed by dealing with the PPG staff. “Trevor Duke (PPG NSW Training Manager) rocked up one day and his knowledge and skills just blew me away. We had a real problem job and he just came in, painted it and did an amazing job. From that day on, I looked up to Trevor.”

Business Support Specialist

Favourite hobbies /pastimes?

Golf Favourite food?

Lamb chops Favourite drink?

Cognac Favourite music / band?

Blink-182 Favourite car / motorcycle?

TA22 Celica / Harley Night Rod Favourite holiday destination?

Dubai

Early on, Andrew took the opportunity to compete in WorldSkills Australia which he won. He then represented Australia at the 2012 WorldSkills event in Germany where he placed an outstanding fourth overall. As his skills and experience grew, Andrew realised he really liked teaching people so moving to a ‘Demonstrator’ role at PPG was a natural progression.

“Every shop is different so I really enjoyed the challenge of working with new people and winning them over with how good our products are.”

Andrew has since moved onto a specialist role helping to support Capital SMART. “We have a set of processes that the PPG team has tailored for speed and efficiency so it’s generally a matter of getting staff to understand the processes and stick to them. One day we might be training a new painter or prepper or it could be training existing staff on new products. I just enjoy going to work every day and taking on whatever R the challenge is.”

CONGRATULATIONS TO ALL THE APPRENTICES WHO PARTICIPATED IN THIS YEAR’S PPG COLOUR MATCHING COMPETITION! Please join us in congratulating our 2019 winners.

1st Place Jarrah Moon – WA South Metropolitan TAFE

2nd Place Aidan Bail – NT Charles Darwin University

3rd Place Maxine Colligan – NSW TAFE NSW Campbelltown

www.ppgrefinish.com.au @ppgrefinishanz @PPGANZRefinish

PPG FLEETPOOL REFINISHER

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Fleet

footed When it comes to offering CT fleet operators a high-quality finish and a comprehensive list of time saving services, PPG’s FleetPool network comes fully loaded.

I

magine you are running a large national Commercial Transport (CT) fleet from your office in Auckland, Melbourne, Sydney, etc. and a company merger means you have to go through a complete relivery project.

This means finding an effective method for ensuring the company’s branding is strong and consistent on all vehicles, from vans and rigid trucks through to prime movers and b-double trailers, which might be spread across the four corners of the country.

Where do you start? In another scenario, say one of your fleet vehicles is involved in an accident in the relative middle of nowhere.

Who can you turn to?.

Unique opportunities When faced with these complications, a growing number of fleets have been turning to PPG’s FleetPool network, according to Fabian Gaida, PPG Market Development Manager. “PPG FleetPool is unique in our market in so many ways. There is no other network that offers the spread of coverage, the consistency and commitment and

is prepared to work together to support customers. It’s a very attractive package for fleet operators because it takes the load off them. Brand image is extremely important to these companies and FleetPool helps them maintain brand consistency whether their vehicle is going to an outlet in Cairns, Hobart, Auckland, Perth, etc. It’s the same products being used, the same colours and the application process which all leads to the same quality end result.”

Fleet partnerships “Each of the FleetPool members are independent businesses but they choose to work as a team. PPG plays its part, too. It gives us a strong, regionwide group with which to approach large fleets and talk to them about how we can assist

with maintaining the presentation of their vehicles. Fleet operators always see it as a positive. In fact, nowadays, the services the PPG FleetPool network provide are so well known, it’s frequently fleet operators who approach us looking for a hassle-free solution. Often, we can be talking about large projects where a trusted partner is essential. For example, after a company merger, we have seen fleets have to relivery as many as 700 vehicles. You need to be dealing with a specialist to get that sort of project done on time and on budget!”

FleetSpec “Each fleet not only has a specific design and colours but also a range of different pieces of equipment it has to go onto.

To cater to this, PPG developed FleetSpec.

Basically, PPG technical specialists will work directly with the fleet operator to create a tailored specification. Whether it’s a rigid truck, a prime mover, a crane or even a boat, we detail exactly how the livery design fits to each vehicle type, the appropriate products

PPG FLEETPOOL 29

REFINISHER

MADE FOR THE LONG HAUL

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ach FleetPool member utilises PPG’s DELFLEET® Evolution paint system which was developed specifically for CT applications.

Virtually every leading truck manufacturer in the world, including Mercedes-Benz, Freightliner, Western Star, Volvo, Mack, Kenworth, MAN, Isuzu, Hino and Mitsubishi, has used Delfleet Evolution to coat literally tens of thousands of vehicles. This is repeated on the local market where PPG supplies truck manufacturers Kenworth, Iveco, Volvo and Mack, as well as major coach and bus makers. Importantly, the Delfleet Evolution system used ‘on-line’ by OEMs is exactly the same product available to refinish users which gives them significant advantages in terms of quickly and accurately matching the original ‘factory’ colour, quality finish and durability.

W H AT I S T H E F L E E T P O O L N E T W O R K ?

P

PG’s FleetPool network is actually a global initiative which started over two decades ago with the aim of giving CT operators access to all the support they need, whether they run a single vehicle or a large national fleet.

It’s made up of carefully selected and accredited independent CT repair and refinish businesses, conveniently situated across Australia and New Zealand.

These professionals specialise in the repair, re-livery (branding change) and refurbishment of heavy vehicles, ranging from trucks and trailers, to buses and other heavy equipment. Importantly, all FleetPool members commit to using best practice processes and the latest technology products and equipment (including PPG paints and the support NT of PPG technical expertise) and are quality certified to ISO 9000 and ISO 16949 standards. The FleetPool network is focused on providing a consistently high standard of service, quality workmanship, on time delivery, integrity, value for money and reduced vehicle downtime, no matter where in the region they are.

WA

to use and the process to get the job done with a high quality end result. We also provide the fleet with colour spray-outs.

Once the fleet operator signs off on it, the FleetSpec manual is distributed to all FleetPool members so that anyone needing to paint any vehicle in the fleet knows the exact systems and colours to use so R that they match every time.”

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QL

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SA

VIC

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PPG COLOUR MATCHING COMPETITION 30

ACEmatch

An

After a hard fought final, it was WA’s Jarrah Moon who took out the prestigious 2019 PPG International Colour Matching Competition.

I

f there was any concern that the skill of colour matching was dying, the latest running of PPG’s International Colour Matching Competition showed it’s well and truly alive and kicking amongst the newer members of the spray painting trade. Although the nine finalists (one from each Australian state and territory, as well as New Zealand) turned up aiming to produce their best performance, they actually seemed more focused on using the experience to add to their growing storehouse

of knowledge on the art of colour matching.

New Zealand competitor, Jesse Pieterse, says it’s about refining the process.

“I have been taking everything onboard and learning from it. I am really just trying to make sure I get the basics of the colour matching process down. It’s not easy but once you understand the colour wheel you start to see the method you need to use.

For example, knowing that this tinter will have this effect, while another tinter will move it in a different direction.”

For the 2019 final, Kangan Institute’s Automotive Centre of Excellence (ACE), in Melbourne’s Docklands precinct, provided an outstanding venue. Each competitor had already won their regional competition earlier in the year so they knew what to expect but the colours chosen for the final threw up some extra challenges. PPG National Colour Auditor, Manny Grillo, says both the solid COB colour and the metallic were based on the modern greys which are coming into vogue with vehicle OEMs. Using the region’s most popular refinish paint system, PPG’s ENVIROBASE® High Performance waterborne basecoat, contestants had 60 minutes to match a COB solid colour and, following a break, 60 minutes to match a metallic colour. To ensure that individual skills were the deciding factor, each finalist had an identical workstation, including all equipment and tinters necessary to match the colours, including a spray-out card of the off-tinted starting colour and another ‘master colour’ spray-out card as a final colour sample. Judging is also done ‘blind’, thanks to final spray-out cards that are numbered, not named. After the pressure of competition, the entire group got to relax a little and try its hand at something different with region wide airbrushing school, Airbrush Venturi,

PPG COLOUR MATCHING COMPETITION 31

REFINISHER

2019 results FIRST PLACE – WA – Jarrah Moon

South Metropolitan TAFE • iPad Air • MIRKA DEROS sander • SATA Vision 5000 hood • Trophy SECOND PLACE – NT – Aidan Bail

Charles Darwin University • Nintendo Switch • Super Smash Bros Ultimate game • MIRKA DEROS sander • Trophy conducted a fascinating ‘introduction to airbrushing’ session.

Afterwards, it was back to the hotel for the evening’s dinner and presentation. Fresh from her performance at the WorldSkills competition in Russia, where she finished an impressive third in the world, New South Wales competitor, Maxine Colligan, took out third place in the final. “With WorldSkills and the regional colour matching competition, I feel like I have not stopped practicing for two years! I actually really enjoy colour matching – I find it fascinating to see how the tinters can affect the colour in different ways.”

Northern Territory representative, Aidan Bail, says that he colour matches every day at work and he used that knowledge to help secure a superb second placing. However, on the day it was Western Australia’s Jarrah Moon who has his name engraved on the trophy. The third-year apprentice, who works at Paull & Warner Accident Repair Centre in Perth, says he doesn’t do that much tinting at work because, in most instances, the

THIRD PLACE – NSW – Maxine Colligan

TAFE NSW Campbelltown • Ultimate Ears Bluetooth Speaker • MIRKA DEROS sander • Trophy FINALISTS (in alphabetical order)

PPG RAPIDMATCH® spectrophotometer or PPG colour chips provide a good colour match. Occasionally, a challenging colour leaves no choice but to tint.

“I thought I did okay in the competition but not brilliant so I was actually surprised when they read out my name. I knew my first colour was pretty good tonal-wise but it was a tiny bit too red. I was not as confident with the metallic colour because the face was looking coarse and dirty but the flip angle was pretty good. I ended up doing R alright, I guess!”

VIC Daniel Chandler GO TAFE Wangaratta SA Lachlan Moseley MTA SA NZ Jesse Pieterse ACT Blake Snow Canberra Institute of Technology QLD Noah Tamala TAS Damien Wing TAFE TAS For winning their way to the final, contestants received a SATAjet X 5500 spray gun. All finalists also received a PPG gift bag of goodies, along with a participation trophy.

1st Place Jarrah Moon WA

3rd Place

2nd Place

Maxine Colligan NSW

Aidan Bail NT

CT REFINISHER

32

Heavenly bodies Drawing on over 50 years of engineering experience, Triple M Truck Bodies has taken the ute tray body market by storm, delivering OE quality, with premium looks and functionality.

U

tes are big business in Australia and New Zealand with an assortment of ute nameplates typically found amongst each month’s top sellers. Indeed, Toyota’s HiLux has been crowned bestselling vehicle in Australia for the past three years,

with Ford’s Ranger taking second in 2017 and 2018. Roles are reversed in New Zealand where Ranger has held top spot for five years and HiLux runner up for the past three. Booming ute sales have seen a corresponding growth in OEMs offering

sturdy and practical accessory tray bodies and it’s here that Triple M Truck Bodies has become market leader, racking up over half a million tray bodies sold!

Short for ‘Manufacturing, Maintenance and Machining’, Triple M was established in 1967 by Gene Thompson who still owns the company. After starting with general engineering, it ventured into aluminium tray bodies in the early ‘70s. Steel tray bodies were added in the late ‘80s and have been the biggest growth product over the past decade or so. The ability to consistently

CT 33

produce durable, high quality ute tray bodies eventually attracted the attention of vehicle OEMs and led to a remarkable list of strong partnerships, according to Michael Fletcher, Design & Development Manager at Triple M. “We currently have contracts to supply 90% of the ute OEMs in Australia. We also supply Toyota, Isuzu Utes and Great Wall in New Zealand, along with low volume exports to countries, such as Thailand and America. Since we started with Mazda back in the late ‘90s, every OEM that has

come onboard with us we have retained, unless they have left the market. Today, around 85% of our business is through OEMs. We believe this is a result of all the hard work that has gone into delivering excellent quality and service at the right price.”

Michael estimates that around 95% of components are made in-house at Triple M’s manufacturing facilities in Stapylton, in south east Queensland. Crucially, each production process, from metal stamping, laser cutting and robotic welding, through to zinc plating, painting and assembly, has been finetuned for high efficiency.

“About ten years ago we started focusing on 5S methodologies. At first,

people saw it as a hinderance to what they were trying to do but, over time, everyone on the production floor has learnt how beneficial it is. And it never stops – we have standardised processes for everything, backed it up with good supervision and we constantly monitor performance.

A comprehensive staff training program fits perfectly with that. Australia wide we have about 270 staff, with about 210 here in Stapylton. From day one, everyone is issued with their training plan and we record training history. We know the area they are going to be working in, what training they will receive and regular follow ups. It’s about quickly getting them working efficiently.”

The ute market’s steady growth has seen a corresponding growth in painted steel tray bodies.

“The percentage of steel trays we produce continues to grow and around 80% are painted. They are pre-galvanised so the customer could buy it unpainted but, today, it’s all about appearance. Nowadays, you can buy a ute with all the latest features, just like a car, and customers typically want the tray painted to exactly match the cab so they get a car like appearance. Part of our contracts with each of the OEMs is to have every one of their vehicle colours formally approved by them. That makes our choice in paint supplier very important.”

Around two years ago, Triple M put its paint supply contract out for tender.

As the rigorous selection process progressed, PPG became the logical choice on so many levels, according to Michael.

REFINISHER

CT 34

Heavenly bodies

REFINISHER

“As well as the ability to test to OEM standards, PPG’s pricing was competitive, as was the quality and appearance.

For me, one of the big things was that PPG manufactures in Australia. I was actually able to visit PPG’s Australian head office in Clayton, Melbourne and see where the products are made and tested.”

Around 18 months to two years before launching a new model, a vehicle OEM will typically approach Triple M. With the specifications of the new model in hand, the Triple M development team can go through the steps to create tray bodies, in aluminium and steel, as well as general purpose and heavy-duty configurations. Subsequently, these trays bodies become part of the OEM’s optional accessories range which customers on the showroom floor can choose to customise their vehicle. Typically, the tray body is supplied and fitted at the dealership before the new vehicle is picked up.

Triple M has to continually adjust to market trends. For example, while singlecab utes are still the biggest sellers, dualcab utes have increased their share of production over the past decade.

Where it used to be split about 90% to 10%, it’s now more like 70% single-cab to 30% dual-cab.

Ensuring that a painted tray body precisely matches the ute it’s being fitted to is a critical part of the development process.

It’s estimated that, across all the vehicle OEMs that Triple M deals with, it has gone through the rigorous colour approval process for almost 250 different colours! It’s here that PPG’s ability to provide a complete package of products and services really cemented the partnership, says Garry Bertie, PPG Business Development Manager Queensland.

“PPG has strong links to virtually every vehicle OEM on the planet so we understand exactly what it takes to work with them. This includes independent testing to OEM specifications covering everything from colour and gloss to stone chipping and chemical resistance. As well as offering products that passed these stringent tests with flying colours, we were actually able to help Triple M Truck Bodies’ production process and excellent end result.

One PPG technology they take advantage of is F4949 CT Productive Chassis Primer Binder which is ideally suited to modern production situations. It meets OEM specifications and features very good build, a high productivity Wet-On-Wet mode and fast curing in as little as 20 minutes! It can also be tinted a sympathetic colour to the topcoat to achieve opacity more quickly, thus saving application time and material.

It really does tick all the boxes!”

To promote efficiency, the Stapylton paint shop comprises three booths where paint is applied before units are moved to separate ovens for baking. This helps give it an overall capacity of about 30 units per day.

Booths have also been installed within the company’s warehouse facilities in Sydney, Melbourne and Adelaide. Instead of having to hold stock of every vehicle colour, this allows unpainted stock to be held and then painted onsite to react quickly to the vehicle colour a customer has ordered.

It’s all part of Triple M’s focus on production and supply chain efficiencies which has not just strengthened the partnerships with OEMs, it has also opened new opportunities, says Michael.

“Recently, we diversified into a new product. We won a contract with Toyota to supply interior van panelling for the new HiAce – basically, like an interior skin in the load area. Having said that, Australia is the biggest ute tray body market in the world so Triple M is not really looking too far from tray R bodies at the moment!”

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