What is the cause of increased defects when production is increased? Compression of drying time.
As the numbers increase, the defect rate skyrockets. We will identify which processes are prone to cuts using data.
The months when production numbers increase are the only times the defect rate skyrockets. It's not that skills have declined; rather, time is being cut. ────────────── ■Cause of Occurrence The first thing to be reduced in increased production is the waiting time for drying and setup. Since waiting time is not visible in the work process, its reduction goes unnoticed. ■The Truth If you cut 5 minutes from the drying after degreasing, moisture remains, leading to adhesion failures. If you compress the retention time in the curing furnace, it results in insufficient hardening, causing stickiness and softening. Defects appear in processes several days later, so the relationship with increased production is not apparent. ■Improvement Measures Clearly state drying and setup as work time in the process chart. Set a daily input limit based on the furnace's capacity, and if exceeded, outsource the excess. Please utilize the process management materials during increased production.
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Corresponding lot: From 1 piece to mass production / Standard delivery time: 5 business days / Process management: Management of process time for degreasing, drying, setting, and furnace retention / Baking temperature: 140-200 degrees / Maximum applicable dimensions: 2000mm
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Maintaining quality in the production plan during the next increase in production and busy periods. We have a track record of handling everything from small lot production to mass production, supporting the utilization of outsourcing during increased production and ensuring process time.
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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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