With the rising cost of raw materials, what is quality control in metal coating to reduce repainting losses?
In an era where paint, energy, and labor costs are rising, effective process management to reduce repainting is essential.
■Cause of Occurrence: In metal coating, invisible costs arise with every defect. Reusing paint, restarting drying ovens, re-inspections, and adjusting delivery dates. Repainting simultaneously increases losses in paint costs, electricity, gas, labor, and inspection man-hours. In an era of rising raw material costs, a single defect cuts into profits. ■Truth: The loss per item may seem small, but repainting 5 out of 100 items results in a defect rate of 5 percent. If this continues weekly, the burden accumulates across all processes. If it leads to delays in delivery or a lack of trust in quality, the losses exceed the numbers. ■Improvement Measures: Not only should defects be identified in the final inspection, but also the degreasing, surface preparation, drying, film thickness, and curing conditions should be checked at each stage to trace back the causes. Issues like pinholes, runs, poor curing, and paint peeling occur simultaneously due to inconsistencies in pretreatment or film thickness. Please utilize materials that can help organize pretreatment, film thickness, and curing conditions.
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basic information
Management engineering: degreasing, surface adjustment, drying, film thickness, curing conditions / Loss factors: paint costs, electricity costs, gas costs, labor costs, inspection man-hours / Defect chain countermeasures: simultaneous management of pinholes, drips, curing defects, and paint peeling / Process records that allow for cause tracking.
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Automotive parts, mass-produced painted products, manufacturing sites focused on cost management.
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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.
