What are the reasons for defects occurring during the first order with a new outsourcing partner? Aligning conditions.
The first lot produced after changing the outsourcing partner has defects. We will specifically organize the conditions that should be met during the transfer.
For the first time after changing the outsourcing partner, the color and luster are different. It's not a matter of skill; it's simply that the conditions have not been carried over. ────────────── ■ Cause of Occurrence Even with the same color number, the appearance changes if the paint manufacturer and film thickness differ. Differences in the material lot from the previous process or degreasing conditions also directly affect the appearance. ■ The Truth Most of the time, only the drawings and color numbers are passed on during the transfer. The film thickness, curing conditions, and color samples used by the previous factory are not carried over. Differences cannot be judged at the initial stage and are discovered only after entering mass production. ■ Improvement Measures We will provide four points: the actual color sample, film thickness range, curing conditions, and inspection standards. The initial run will be done in small quantities, and we will determine pass or fail through actual sample comparison before moving on to mass production. Please utilize the checklist for outsourcing transfers.
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Transfer items at the time of handover: physical color samples, film thickness range, curing conditions, inspection standards / Color management: color sample verification, color difference measurement support / Construction methods: solvent-based baking paint, powder coating / Corresponding lots: from 1 piece to mass production.
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Switching of painting subcontractors, establishment of a second procurement source, and quality confirmation during production transfer. There is a track record of supporting the startup through physical verification of color samples and initial small-scale production runs.
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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.
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