Even though it's the same procedure manual, only the newcomers are producing defects. I will articulate the three key points that are not written in the manual.
Even though the same procedure manual is provided, only the newcomers are producing defects. What is lacking is not experience, but the ability to articulate. ────────────── ■Cause of Occurrence The procedure manual contains numerical values, but the rationale for the judgments is not included. Without knowing why those values are set, one cannot respond when conditions change. ■Truth The most common defects among newcomers are related to gun distance, operating speed, and overlap width. A difference of just 5 centimeters in gun distance can change the film thickness by 20%. Experienced individuals unconsciously make adjustments, so those teaching may not even realize this. ■Improvement Measures Clearly specify the gun distance, operating speed, and overlap width with numerical values, and have them confirmed with actual items. Keep defective products as teaching materials and show the causes and conditions together. Please utilize the management item checklist for newcomer training.
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Target of Education: Gun distance, operating speed, overlap width, viscosity, film thickness, curing conditions / Corresponding Methods: Solvent-based baking paint, powder coating / Support Content: Management item checklist, defective samples, process record format
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Training new employees at the painting site, creating educational curricula for the HR department, and providing technical guidance to partner companies. I have a track record of supporting the verbalization of decision-making criteria not written in procedure manuals and the development of teaching materials.
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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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