What is the cause of only the first batch of products in the morning being defective? Furnace startup.
Only a few defects occur right after the start of operations. I will explain the management methods until the furnace and booth reach a steady state.
Only a few pieces right after starting production consistently have defects. The operators are the same. The difference is the temperature of the equipment. ────────────── ■ Cause of Occurrence Both the curing furnace and the booth are not stable immediately after startup from a stop. Even if the displayed temperature reaches the set point, the furnace walls and jigs remain cold. ■ Truth When the furnace walls are cold, they draw heat from the product, lowering the actual curing temperature. Until the booth's air conditioning stabilizes, the humidity is also high, making defects more likely. The recorded temperature reflects the set value, so the cause remains unidentified and repeats. ■ Improvement Measures Decide on a pre-heating time before starting production and preheat each jig before running them through. For the first few pieces, only run waste boards or jigs, and once conditions stabilize, proceed with the main flow. Please utilize the standardization materials for the startup procedure.
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Corresponding construction method: solvent-based baked coating, powder coating / Baking temperature: 140-200 degrees / Startup management: setting empty burning time, jig preheating, initial product confirmation / Records: management of furnace wall temperature and actual product temperature / Inspection: confirmation of all initial products
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Quality control of a painting line with multiple varieties and small lot production, which stops the furnace daily. We have a track record of supporting the standardization of preheating time and waste flow in response to concentrated defects right after the start of operations.
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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.
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