With the vast varieties of paint, materials and application processes, the achievement of an efficient, high-quality and consistent automated painting process can often seem elusive. How can the director of the painting operation optimize output and quality while controlling costs? Output is useless without quality. The cost of scrap and rework adds up quickly, and can delay the overall project. For example, if a painted plastic bumper cover has flaws and needs to be reworked or scrapped, then that component will not be available for assembly to the designated automobile, potentially impacting the production line or the customer (and who wants rework stacking up?). This is a disruptive and costly nuisance.