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). Insufficient management of cleaning solutions is the main cause: 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 replaced for more than two weeks, the contamination rate jumps 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 state. 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 nearly 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.
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Cleaning solution management, filter replacement, water supply management, cleanliness management.
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Reduction of foreign matter contamination, quality assurance
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Company information
We are not just a "subcontracted painting factory." Established in 1958, our company has a foundation of painting technology and also specializes in chemical treatment, stripping, and cleaning, functioning as the "external surface treatment department" in your organizational chart. Based on our philosophy of "preparation is eight-tenths of the work," we emphasize participation from the "upstream process" before the drawings are finalized. We conduct test painting on a wide range of metals and difficult materials, and we produce the entire process from assembly, packaging, to delivery, thereby reducing your management workload. Additionally, by being able to perform zinc phosphate treatment in-house, we achieve stable painting quality. Furthermore, our micro-heating stripping technology, which does not use chemicals, maintains the electrical state of the "jigs (hangers)" that influence painting quality. Our approach of "pre-treatment determines painting quality" ensures the stability of the paint film during mass production. Rather than simply "applying specified standards," we work backwards to achieve optimal painting specifications and prevent scratches during transportation, sparing no effort in thorough discussions from the outset. This diligent preparation is the shortest path to preventing rework and minimizing total costs. From the development stage, please utilize the expertise of our specialists as part of your production line.
