Possible Tests For Paint tanks

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    Hi all, We are the largest leaf spring manufacturer in North America. We use dipping paint tanks for painting our springs. The only test we are currently doing is viscosity check. Please advise for the following
    1- What other possible tests we can do?
    2- Second problem is, we get a lots of customer issues for missing paint in springs. Reason is we dip the whole pallet in tank. The bottom ones have sometime missing paint issue.
    Appreciate your replies. Thanks



    What other factors can affect your results? Temperature? Dwell time?
    A straightforward cause-and-effect analysis with an Ishikawa diagram
    should be very helpful.DLW – BPEX



    Try to track the level of Paint tank , if that effects your Activity , what other complaints you receive from the customer.



    When you dip components into a tank, you take in more than the components. You take air in between the components and whatever is sitting on the product. So you should ask yourself: are the components clean and wet-able; how can I un-trap, trapped air while the components are under all that gloob :-)Good luck ..



    Please ask yourself about all opprtunities which could affect for final product quality through your paint process like paint level, temp, time, pollution, immersion time durst on part etc…….
    You will get a list of potential x’s to sort
    From this list collect the potential occurence will generate a potential defect than decide which x’s you will investigate and measure
    In summary VOC + fishbone + first part of FMEA will give you all information you need



    It sounds like to need to define the problem better before you go down a root cause and x-factor path.  You should spend some time developing a good definition of what is a “good paint condition” and a “nonconforming paint condition”;  in addition to a visual definition, also try to develop a variable measure of paint (e.g., paint thickness gaging).  You will probably find that you have different types of ‘defects’ occurring in the process, so attacking all of the potential x-factors is a shotgun approach. 
    Once you have the definitions, understand what type of variation is occuring in the process (what is the within spring variation? variation between springs in a batch? variation between batches of springs?);  develop a measles chart of the variation; then develop a pareto of defects by location, types, products, etc.  This will lead to the questions that you need to ask that meet the variation that you are seeing — (for example, if your viscosity remains constant batch-to-batch, but your defect type varies significantly batch-to-batch, then is viscosity the significant factor causing this variation?) At this point, you will be ready to identify potential x-factors that relate to the major defect types/characteristics.

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