The cause of complaints regarding aluminum die-cast painting was contamination by foreign substances.
70 percent of foreign matter contamination is caused by the cleaning process. It is possible to reduce it by 99 percent through filter replacement and cleaning solution management.
Foreign matter contamination is a phenomenon where dust, oil, moisture, and other debris attached to the paint film result in defects. If discovered during the inspection process, it incurs costs of 300,000 to 500,000 yen for re-cleaning and repainting, and if overlooked and delivered, it leads to customer complaints (return rate: 20-30 percent). The main cause is insufficient management of the cleaning solution: when the viscosity of the cleaning solution is high, fine debris settles and adheres to the product surface upon reuse. If the cleaning solution is not changed for more than two weeks, the contamination rate can soar to 70-80 percent. Quantifying filter efficiency: after using a filter for 500 hours, the filtration efficiency decreases by 60 percent compared to the initial value. By replacing the filter every 250 hours, the contamination rate can be maintained below 0.5 percent. Contamination countermeasures from the water supply pipe: fine scale and rust in the water supply can be dispersed by air blow and adhere to the product in 25 percent of cases. Regular replacement of the water supply filter (once a month) can virtually eliminate contamination from this route. Our company replaces the cleaning solution every five days, manages filters for 250 hours, and conducts monthly replacements of the water supply filter. The contamination rate is below 0.2 percent.
- Company：永和工芸
- Price：Other
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