It is important to manage preprocessing, film thickness, and baking conditions through records, rather than relying solely on the intuition of skilled practitioners.
■Cause of Occurrence: In metal coating, the shortage of manpower and the difficulty of skill transfer lead to quality defects. Experienced workers can notice residual oil, excessive film thickness, insufficient drying, and areas prone to dripping, but inexperienced workers may overlook these issues. Coating peeling, pinholes, poor curing, and blisters occur due to the accumulation of small variations in judgment. ■Truth: The danger of manpower shortages lies not only in the number of workers but also in the fact that judgment criteria can vary from person to person. If film thickness is judged by feel, curing conditions are not recorded, and drying conditions are assessed only visually, the same defects cannot be prevented. Clear standards that anyone can understand are necessary. ■Improvement Measures: Record degreasing conditions, drying times, film thickness measurements, curing temperatures, and inspection results, and standardize the three aspects of work procedures, inspection criteria, and defect confirmation procedures. Please utilize materials that allow you to verify pretreatment, film thickness, and curing conditions.
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Record items: De-fatting conditions, drying time, film thickness measurement, curing temperature, inspection results / Three standardizations: Work procedures, inspection criteria, confirmation procedures in case of defects / Defect countermeasures: Paint peeling, pinholes, curing failure, blistering / Skill inheritance response
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Automotive parts, mass production painting site, small lot production of various types, site with skill inheritance issues.
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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.
