Gloss Boss cab Paint,25.08.16.pptx

1 5/25/2017 Ashok Leyland Presentation
Paint Exterior appearance (Gloss)
improvement in Boss Cab
CQ: Cab Paint ,PNR
QC Story

Content
 Problem
 Observation
 Analysis
 Actions
 Check
 Standardization
 Conclusion

Benchmarking
Gloss Level
G
L
O
S
S
9
2
8
8
9
3
9
3
9
3
9
4
9
6
8
8
8
6
9
0
9
2
9
4
9
6
9
8
10
0
AL @PNR-
BOSS
,Before
TATA-
ACE
AL-
Dost
AL@AALM-
AVIA
Bharat
Benz
Maruti -
Ertiga
Honda-
City
Gloss Level %
Commercial vehicle Passenger Car

Problem Identification
Step 1- Problem
Back Ground of the problem
93
92
95
96
95
94
93
92
91
90
BM (AALM-AVIA) Actual Boss@PNR Target
Gloss Level %
 92 % Gloss level low in PNR Produced Boss Cabs

Theme & Target
Theme & Target:
Step 1- Problem
• Perceived Quality
Why
• Low Gloss level in “BOSS“ Truck Cabin @ALP
What
• Gloss level = 92% , Target = 95%
How

Step 1- Problem Team Formation
Team Members:
Facilitator : Ramakant Sharma
Leader : Shivpujan Gupta
Members : Mukesh Rawat
Swati Rawat
Pooja Dewari
Deepak Pant

 Presently We are producing 03 models (Boss, G91 & Captain)
ED
SANDING
TOP COAT
PREPARATION
PT LINE ED LINE
SEALANT LINE
PVC LINE
TOP COAT LINE
TOP COAT STORAGE
INSPECTION
POLISHING
WAX
INPUT FROM
WELD ( BIW )
TO TRIM
PAINT
KITCHEN
QG-1
QG-2
QG-3
QG-4
QG-5
Step 2- Observation
Painting Process Flow
Gloss
Measurements

Step 2
Observation
MSA for Gloss
Measurement Variation : Gauge R & R Study:
MSA study is performed for Gloss-meter, to understand the %age variation within
appraisers and between appraisers.
100
75
50
Deepak Swati
2
1
0
Variation Breakdown
%Process
R Chart of Test-Retest Ranges by Operator(Repeatability)
Operators and parts with larger ranges have less consistency.
Reproducibility — Operator by Part Interaction
Look for abnormal points or patterns.
100 Source StDev (data)
Total Gage 0.471 2.16
75 Repeatability 0.364 1.67
Reproducibility 0.298 1.37
Part-to-Part 21.819 99.98
50
Process Var (data) 21.824 100.00
Reproducibility — Operator Main Effects
Look for operators with higher orlower averages.
100
75
50
Deepak Pooja Preety Swati
Gage R&R Study for Measurements
Variation Report
Xbar Chart of Part Averages byOperator
At least 50% should be outside the limits. (actual: 100.0%)
Pooja Preety
Results:
Repeatability = 1.67%
Reproducibility = 1.37 %, the result shows that we can adequately
measure process performance
Measurement (R&R) variations are so less or
negligible so we can go for process variation.
Status:

Step 2- Observation
Problem Definition
 Low Gloss in Boss model: 92 %
 Gloss measurement on daily basis at below location: X1, X2, X3 & X4
X3 X1 X2 X4
B- Class Area *A- Class Area B- Class Area
Gloss Data collection for Only A-Class Area
*Why A-Class area? : A-Class Area coming in direct eye contact ofcustomer

93.5
93.0
92.5
92.0
91.5
X2
The mean of X1 is not significantly different from the mean
of X2 (p > 0.05).
0 0.05 0.1
Yes
> 0.5
No
P = 0.815
-0.1 0.0 0.1 0.2
-0.2
-- Test: There is not enough evidence to conclude thatthe
means differ at the 0.05 level of significance.
-- CI: Quantifies the uncertainty associated with estimating
the difference from sample data. You can be 95% confident
that the true difference is between -0.14944 and0.18944.
-- Distribution of Data: Comparethe location and means of
samples. Look for unusual data before interpreting the
results of the test.
Distribution of Data
Compare the data and means of the samples.
X1
Do the means differ?
2-Sample t Test for the Mean of X1 and X2
Summary Report
Statistics X1 X2
Sample size 50 50
Mean 92.362 92.342
95% CI (92.22, 92.51) (92.250, 92.434)
Standard deviation 0.50825 0.32331
Difference between means* 0.02
95% CI (-0.14944, 0.18944)
* The difference is defined as X1 -X2.
95% CI for the Difference
Does the interval include zero?
Comments
Step 2- Observation
ANOVA
 Location X1 & X2 are
symmetric for painting
 No Significant Difference in
Gloss level
02 Sample t-test for X1 & X2 location :
So we can consider X1 & X2 location as 01 subgroups

Step 2- Observation
Data Collection
1). Sample Size– 50, 2). Sub Group Size-02, 3). Avg. Value - 92.3 4). Process isstable
X1
X2
C ab-1 C ab-6 C ab-11 C ab-16 Cab-21
93.5
93.0
92.5
92.0
91.5
Cabin
Sample
Mean
_
X=9 2.352
UC L=93.246
LCL=91.458
1.6
1.2
0.8
0.4
0.0
Cabin
Sample
Range
_
R=0 .475
UC L=1.553
LCL=0
For the initial gloss level we have taken Gloss Data of 50 cabins to analysis the processstability.
We have observed process was stable & gloss mean value ~92%
Daily Quality Check Sheet
Xbar-R Chart of Gloss Level

Step 2- Observation
Cause and effect diagram: Level 1
MAN
MACHINE
METHOD
MATERIAL
Robot
Voltage
Booth
Temperatur
e
Booth
Humidity
Additives of
Topcoat
Post Touch-
up manual
Paint
Application
Tag-o-Rag
Method
No. of
Coatings
Viscosity
Painting
skill
RobotFlow
Rate/
pattern
Robot
Preventive
Maintenanc
e
Painting
Application
Angle
Sanding&
Polishing
Polishing
Material
PT-ED Material
Low Gloss
ED & Top
coat DFT
Sheet
Roughness
Cab wiping
Lux level in
Top coat
booth
Top coat
Booth
Balance
Paint
resistivity
Topcoat
Paint
Material
Slow
thinner
Solvent
Evaporation
rate
Phosphate
Roughness
Training /
Painting
experience
Robot
Teaching
Gun Pattern
Paint
formulation
EDBath
Solvent
Paint
Potential Cause
Non-Potential Cause
To analyze Process variation causes we have done brain storming through Fishbone diagram as below Shown
and rectified 08 potential causes :

Step 2- Observation
Cause and effect diagram : Level 2
Significant cause & Effects for Low Gloss:
MAN
MACHINE
METHOD
MATERIAL
Booth
Temperature
Booth
Humidity
Robot Flow Rate/
pattern
Additives of
Topcoat
ED Bath
Slow Thinner
Paint
Viscosity
Post Touch
up
Low Gloss
1
4
7
5
3
2
8
6
*Sequence numbers (1* to 8)
Given as per PaintingProcess
Flow ….

Step 3-Analysis
Causes Validation :
Cause Validation through Placket Screening Analysis :
1. No. of factors- 08, No. of levels-2, No. of runs- 12
Factors Corresponding to red arrows are Significantfactors

Step 3-Analysis
Trials:
After Elimination of Insignificant Causes from Placket Screening:
Now according to placket screening 88.55% Variation in Gloss is due to 04factors:
a)ED Bath Solvent%, b) Robot Flow Rate, c) Slow Thinner, d)Paint Viscosity

Sl. No. Factors Difficulty Remark
1 Solvent %
Pilot Batch preparation in scale down
model Solvent addition as per design ~04 hour per Run ( Refer the Example)
2 Flow Rate Flow rate adjustment in all runs
01 hour per Run for manual flow
rate adjustment & application
3 Slow Thinner Slow thinner addition as per Design ( in Pot Quantity) 30 minute per run for pot quantity
4 Paint Viscosity Viscosity setting in all runs ( in Pot Quantity) 30 minute per run
5 Touch/Up No -------
6 Booth Temp. No, Automation is there -------
7 Booth Humidity No, Automation is there -------
8 Additives No -------
Step 3-Analysis
Placket Screening Model:
StdOrde
r
RunOrder PtTyp
e
Blocks Solvent % Flow Rate
Slow
Thinne
r
Paint Viscosity Touch/Up Booth Temp. Booth
Humidity
Additives Gloss
%
3 1 1 1 1 400 3 24 yes 25 55 no 96.2
1 2 1 1 2.5 300 3 24 no 25 75 yes 95.8
5 3 1 1 2.5 400 1 26 yes 25 75 no 95.4
11 4 1 1 1 400 1 24 no 30 75 yes 93.5
4 5 1 1 2.5 300 3 26 no 30 55 no 95.2
10 6 1 1 2.5 300 1 24 yes 30 75 no 94.2
12 7 1 1 1 300 1 24 no 25 55 no 92.2
7 8 1 1 1 400 3 26 no 30 75 no 93.9
6 9 1 1 2.5 400 3 24 yes 30 55 yes 97.5
2 10 1 1 2.5 400 1 26 no 25 55 yes 93.6
9 11 1 1 1 300 1 26 yes 30 55 yes 90
8 12 1 1 1 300 3 26 yes 25 75 yes 93.2
Below Challenges faced to follow Placket Screening Design :

Challenges for solvent % changes in ED paint bath main tank
Panel to be coated (-)
ED bath (+)
(to be circulated continuously)
We can not take
the risk of any
abnormality in
main tank.
ED paint main bath tank
volume is 1,71,000Liter.
ED tank
We can
simulate the
same exercise
in Scale down
Bath
 To make Scale Down bath with Different Solvent % level (~4 hours for one experiment)
 Pilot Scale Down batch of 02 liter ED Bath Preparation with DI Water, F1 & F2
Solution.
 Homogeneous mixture for bath maturity
 Added solvent % as per run
 Final Panel Preparation
 Baking in Lab Oven
ED coated panel
Reference pic.

Causes Validation :
Step 4-Action
These 04 factors taken up in a full factorialdesign to optimize the value of Gloss level:
No. of factors- 04 ,No. of levels-2, No. of runs- 32 [ N=(LF ) R ], Replicate=02
Factors Corresponding to red arrows are Significantfactors

Causes Validation :
Step 4-Action
Elimination of insignificant causes one by one from Full factorial Design:
As per full factorial DOE conducted in ACTION phase,80.57 % Variation in Gloss Due to :
1. ED Bath Solvent%
3. Slow Thinner
2. Robot Flow Rate
4. Solvent% * Paint Viscosity
5. Robot Flow Rate * Paint Viscosity

Optimization of parameters :
Step 4-Action
After elimination of insignificant causes from Full factorial Design, we have optimized all
significant causes as below table:
Factor Optimization
Factors
Before DOE
The
process
parameter
range
Output
from DOE
Process
correction
after
optimization
( Engg.
Trials)
Why we
cannot go
beyond this
parameter
range
ED Bath
Solvent%
1.0 – 2.0 2 1.8 – 2.2
Poor adhesion &
High cost
Robot flow
rate
300 - 450 400 380 - 420
Sag issue &
high cost
Slow thinner
%
Nil 1 0.5 – 2.0
Sag issue on
curve area
Paint
Viscosity
20 - 26 22 20 - 24
Sag issue at <
20 viscosity
Gloss% 91.9 95.3 >95 --

Slow Thinner
container
Challenges for Slow thinner % & Viscosity adjustment
 Paint Preparation in Paint Kitchen: (~3 hours)
 Slow solvent % introduction in mixing tank
 Homogeneous mixture of paint & solvent
 Viscosity adjustment as per DOE
 Transfer the paint in main tank for robotpainting
 Paint application by robot & bake the cabin inoven
 Final output check on cabin

Challenges for Robot Flow rate adjustment
 Flow rate adjustment in Robot: ( ~3 hours for one experiment )
 Robot Flow rate adjustment as per
DOE output at required brush level
based on location / class ofcabin.
 Top-coat Painting on cabin as per
DOE output
 Oven baking & Result check
Top coat paint application
by Robot

Step 5-Check
Result Confirmation
Gloss level After all optimization
Daily Check Sheet
1. Sample Size– 45, 2. Sub Group Size-02, 3. Avg. Value - 95.4 , 4. Process isstable
X1
X2
96
95
94
C ab-21 C ab-25 C ab-29 C ab-33 C ab-37 C ab-41 C ab-45
Cabin
Sam
ple
M
e
a
n
_
X=95.324
UC L=96.594
LCL=94.055
2.0
1.5
1.0
0.5
0.0
C ab-21 C ab-25 C ab-29 C ab-33 C ab-37 C ab-41 C ab-45
Cabin
Sam
ple
Range
_
R=0.675
UC L=2.206
LCL=0
Xbar-R Chart of Gloss Level After

Bench Marking
Gloss Level
G
L
O
S
S
9
2
8
8
9
3
9
3
9
3
9
5 9
4
9
6
8
8
8
6
9
0
9
2
9
4
9
6
9
8
10
0
AL @PNR-
BOSS
,Before
TATA-
ACE
AL-
Dost
AL@AALM-
AVIA
Bharat
Benz
AL @PNR-
BOSS,
After
Maruti -
Ertiga
Honda-
City
Gloss Level %
Commercial vehicle Passenger Car

Gloss Evaluation by Top Management After Implementation
Evaluated By
1. Head Operations
2. SD-CQ
3. AALM, AVIA Team
4. PD – PNR
5. CQ Head –PNR
6. BU Head- Cab & Team
Comments: Orange peel & Gloss has improved
and maintain the same levelfor
mass production.

4. Revised Control plan: ED solvent level
Step 6- Standardize
1. Solvent Level spec revised from 1.0~2.0 % To
1.5~2.5% .
2. Daily Gloss Monitoring.
3. Daily Thinner Combination Check SheetIntroduced
5. Revised Control plan: Top Coat Glosslevel
6. Revised Control plan : Paint Kitchen
3. Daily thinner
Combination Check
Sheet
T O ,
M r . Ri shi kant Si ngh D A T E :- 3 . 0 7 . 1 3
M / s M / S A L L - P a n t n a g a r P a in t S h o p
C E D B A T H S A M P L E A NA L YS IS B Y M / S . K NP
C H E C K E D B Y: - M. K . G
c c : E D L a b Mumbai .
R E M A R K S : - P lease main t ain A S H % a b o v e 2 3 % .
T est ed B y: Y. K . S h a r m a F o r K A N S A I N E R O L A C P A I N T S L T D .
( N A V E E N K U M A R )
K A N S A I N E R O L A C P A I N T S Ltd
B A W A L P L A N T , P l o t N o . 3 6 S e c t o r - 7 H S I D C G r o w t h C e n t e r B a w a l 1 2 3 5 0 1 D i s t . R e w a r i , ( H ar y a na )
T EL EP HONE N O - 0 1 2 8 4 - 2 6 1 7 0 7 ;
S amp le D at ed : 24. 06. 13
S amp le R eceived : 1. 07. 13
S . N o . T est It ems S p ecificat io n R esu lt R e m a r k
1 Non - Volatile C ontent 1 8 ~ 2 2 % 20. 27 O K
2 A S H C ontent 2 0 ~ 2 4 % 21. 90 O K
3 p H 5. 7 ~ 6. 3 5. 70 O K
4 S p. Conductivity 1 3 0 0 ~ 1 9 0 0 1 6 2 0 O K
5 M E Q 2 4 ~ 3 2 26. 56 O K
6
S olvents A naly si s
Total % 1. 5 ~ 2. 5 2. 06 O K
1. Solvent Level
Revised
2. Daily Check
sheet forGloss
C h e c k e d
B y ( B U )
A p p r o v e d
B y ( B U )
P r e p a r e d B y ( C F T )
P r e p a r e d B y ( C F T ) C h e c k e d
B y ( U P )
A p p r o v e d
B y ( U P )
S i z e F r e
q .
P r e v e n t i o n / E r r o r
P r o o f i n g
D e t e
c t i o n
1
g r e a t e r t h a n
9 0
G l o s s o f
t o p c o a t
p a i n t e d
c a b i n s h o u l d b e
G l o s s o m e t e r - - - -
- - - -
A s p e r
Q u a l i t y
- - - - A u d i t S c h e d u l e
P / P A / C Q / F -
0 0 6 )
N o n e
* I n c a s e Q C i n c h a r g e f i n d s t h e g l o s s o f p a i n t e d
c a b i n t b e o u t o f s p e c i f i c a t i o n , t h e n i n c h a r g e
n e e d s t o i n s t r u c t t h e p o l i s h i n g l i n e o p e r a t o r t o
d o t h e p o l i s h i n g o f t h e w h o l
n o n - c o n f o r m i n g c a b i n .
G l o s s t e s t i n g b y Q C i n c h a r g e
* A f t e r w a r d s , t h e Q C i n c h a r g e n e e d s t o r e c h e c k
t h e
a n d r e c o r d i n g o f o b s e r v a t i o n s
g l o s s o f t h e c a b i n . I f t h e g l o s s i s f o u n d t o b e
O K , t h e n h e
i n D a i l y q u a l i t y c h e c k s h e e t
n e e d s t o s e n d t h e c a b i n t o w a x b o o t h f o r f u r t h e r
( P / P A / C Q / F - 0 1 3 )
p r o c e s s i n g . I n c a s e t h e g l o s s i s N O T O K , t h e n t h e Q C i
c h a r g e n e e d s t o i n f o r m t h e l i n e i n c h a r g e a n d
i n s t r u c t h i
t o d o d r y s a n d i n g a n d r e - p a i n t i n g o f t h e c a b i n .
* A f t e r r e - p a i n t i n g , t h e l i n e i n c h a r g e n e e d s t o
g e t t h e a p p r o v a l f r o m Q C a n d t h e n o n l y s e n d
t h e c a b i n f o r f u r t h e
p r o c e s s i
n g .
2
T o p c o a t
p a i n t
0 / 1 0 0 i n
a d h e s i o n
t e s t
t e s t e r
f i l m s h o u l d p a s s C r o s s H a t c h
- - - - - - - -
A s p e r
Q u a l i t y
- - - - A u d i t S c h e d u l e
P / P A / C Q / F -
0 0 6 )
N o n e
* I n c a s e o f a d h e s i o n f a i l u r e , t h e Q C i n c h a r g e
n e e d s t o i m m e d i a t e l y s t o p t h e l i n e a n d c h e c k
t h e a d h e s i o n o f a l l t p r o c e s s e d c a b i n s f o r t h a t
d a y . I f t h e a d h e s i o n t e s t i s f o u O K i n r e s t , t h e n
h e n e e d s t o o n l y q u a r a n t i n e t h e n o n - c o n f o r m i
n g c a b i n a n d p e r f o r m s o l v e n t t e s t o n t h e s a m e
c a b i n . I f s o l v e n t t e s t r e s u l t s a r e f o u n d t o b e N O T
O K , t h e a d h e s i o n t e s t o f t o p c o a t t h e Q C i n c h a r g e n e e d s t o i n s t r u c t
t h e l i n e i n c h a r g e t o
p a i n t e d c a b i n u s i n g c r o s s r e b a k e t h e s a m e c a b i n .
h a t c h t e s t e r b y Q C i n c h a r g e * T h e l i n e i n c h a r g e n e e d s t o r e b a k e t h e
c a b i n b y p a s s i n a n d r e c o r d i n g o f o b s e r v a t i o n s t h r o u g h o v e n a n d
t h e r e a f t e r g e t t h e s a m e r e - i n s p e c t e d b
i n D a i l y q u a l i t y c h e c k s h e e t C r a f t e r t h e a p p r o v a l o f Q C o n l y , h e c a n
s e n d t h e c a b i n t ( P / P A / C Q / F - 0 1 3 ) w a x b o o t h f o r f u r t h e r p r o c e s s i
n g .
* I n c a s e t h e r e s u l t s o f s o l v e n t t e s t a r e f o u n d t o
b e O K , t h e n t h e Q C i n c h a r g e n e e d s t o i n s t r u c t
t h e l i n e i n c h a r g e
f o r d r y s a n d i n g f o l l o w e d b y r e p a i n t i n g o f t h e
c a b i n .
* T h e l i n e i n c h a r g e a f t e r r e p a i n t i n g o f t h e c a b i n
n e e d s t o
g e t t h e a p p r o v a l o f Q C a n d t h e n o n l y s e n d t h e
c a b i n f o r f u r t h e r p r o c e s s i n g .
E a c h
C a b
1 0 0 %
E a c h
C a b
1 0 0 %
a s p e r c a b
p a i n t
1 q u a l i t y s c h e d u l e
( P / P A / C Q / F -
0 0 6 )
D a t e :
1 5 . 1 1 . 1 3
D a
t e
3
P a r t N o . / L a t e s t c h a n g e L e v e l : 1 . B 0 Y 0 0 6 0 1 /
B 0 Y 0 0 8 0 1
2 . B 0 Y 1 7 7 0 1
C o r e T e a m : R o h i t , D e e p a k , L a k h v i n d e r K a u r , R i s h i , A j a y , M u k e s h , S h i v C u s t o m e r E n g i n e e r i n g A p p r o v a l
D a t e ( I f R e q u i r e d ) :
P u j a n , A k s h a n s h , J o y G u r u
S p e c i a
l
M e
t h o d s
S u p p l i e r P l a n t : S u p p l i e r
C o d e :
O t h e r A p p r o v a l D a t e ( I f R e
q u i r e d ) :
O t h e r A p p r o v a l D a t e ( I f R e
q u i r e d ) :
S u p p l i e r P l a n t A p p r o v a l
D a t e :
C u s t o m e r Q u a l i t y
A p p r o v a l :
S a m p l e
S i z e
O p e r a t o r
S a m p l e S i z e I n s p e
c t o r
S i z e F r e q .
P a r t / P r o c e s s N a m e /
M a c h i n e , D e v i c e ,
P r o c e s s O p e r a t i o n
J i g , T o o l s f o r M f g .
N o . d e s c r i p t i o n
C h a r a c t e
r i s t i c
t h e p a i n t e d c a b i n
2 6 0
I n s p e c t i o n a n d p o l i s h i n g p a d ,
s h o u l d b e f r e e f r o m
P o l i s h i n g c o n v e y o r , p o l i s h e r
p a i n t i n g
d e f e c t s
C o n t r o l M e
t h o d R e a c t i o n P l a n i n c l u d i n g c o r r e
c t i v e a c t i o n
N o . P r o d u c
t
P r o c e
s s
v i s u a l c h e c k i n g b y p o l i
s h i n g l i n e o p e r a t o r a f t e r
r e c t i f i c a t i o n
a n d r e c o r d i n g o f s a m e i n s e l f
* I n c a s e p a i n t s a g i s p r e s e n t o n t h e p a i n t e d
c a b i n , t h e n
c e r t i f i c a t i o n c a r d ( ( P / P A / M / F -
t h e o p e r a t o r n e e d s t o f i r s t t r y
d o i n g s a n d i n g o f t h e
0 3 0 & P / P A / M / F - 0 3 3 ) )
a f f e c t e d p o r t i o n ( i n c a s e i t i s o f v e r y s m a l l g r a d e )
f o l l o w e
v i s u a l c h e c k i n g b y Q C g a t e
b y s u b s e q u e n t p o l i s h i n g . I f t h e d e f e c t i s r e c t i f i e d ,
t h e n t h
o p e r a t o r a t p o l i s h i n g s t a g e f o r
o p e r a t o r n e e d s t o s e n d t h e r e c t i f i e d c a b i
n t o W a x b o o t h
p a i n t i n g d e f e c t s a n d
f o r f u r t h e r p r o c e s s i n g . W h e r e a s i f t h e d e f e c t i s t i l l n o t
r e c o r d i n g i n d e f e c t s c h e c k
r e c t i f i e d , t h e n t h e s a m e d e f e c t e d C a b i n n e e d s t o
b e s e
s h e e t ( P / P A / C Q / F - 0 0 4 )
t o S p o t r e p a i r b o o t h f o r t o u c h u p . A f t e r
a p p r o v a l f r o m Q
, t h e c a b i n n e e d s t o b e s e n t t o W a x b o o t h f o r f u r t h e r
p r o c e s s i n g .
* I n c a s e t h e g r a d e i s h i g h , t h e n t h e c a b i n n e e d s
t o b e s e n t t o d r y s a n d i n g b o o t h f o r r e w o r k
o f t h e i d e n t i f i e d p o r t i o n . A f t e r r e w o r k , d r y
s a n d i n g l i n e o p e r a t o r n e e d s t o s e n d t h e s a m e
c a b i n t o t o p c o a t b o o t h f o r r e p a i n t i n g .
* I f Q C g a t e o p e r a t o r d e t e c t s a s i m i l a r n o n
c o n f o r m i n g c a b i n i n p o l i s h i n g l i n e , t h e n t h e
g a t e o p e r a t o r n e e d s t o
d u r i n g p r o d u c t a u d i t
t h e Q C o p e r a t o r n e e d s t o i n f o r m l i n e i n
c h a r g e .
q u a l i t y i n s p e c t i o n b y Q C i n
s e n d t h e c a b i n t o t o u c h u p b o o t h f o r m i n o r
g r a d e .
c h a r g e f o r p a i n t i n g d e f e c t s
* I n c a s e t h e n o n - c o n f o r m i t y i s o f h i g h e r
g r a d e , t h e n t h e n
( P / P A / C Q / F - 0 0 3 )
* L i n e i n c h a r g e n e e d s t o s e n d t h e c a b i n t o d r y
s a n d i n g
b o o t h f o r r e w o r k f o l l o w e d b y r e p a i n t i n g o f t h e
c a b i n i n t o p c o a t b o o t h . A f t e r r e p a i n t i n g , t h e
Q C g a t e o p e r a t o r n e e d s t o r e - i n s p e c t t h e
c a b i n a n d o n c e i t i s O K , t h e n o n n e e d s t o
s e n d t o w a x b o o t h f o r f u r t h e r p r o c e s s i n g .
c h a r a c t e r i s t i c s
P r o d u c t / P r o c e s s E v a l u a t i o n
S p e c i f i c a t i o n M e a s u r e
m e n t
T o l e r e n c e s T e c h n i q u e
s
n o s a g g i n g o f
V i s u a l
p a i n t
P a r t N a m e / D e s c r i p t i o n . : 1 . G 9 1 C A B I N
( S L E E P E R A N D D A Y ) 2 . B O S S
C A B I N
Pre -La unch Production
Approved By(BU)
Approved By(UP)
Size Freq. Prevention / Error Proofing Detection
1 A ppl i c at i on V i s c os i t y
2
Tem perat ure of P ai nt
Thi nner Mixture
Rat i o of P ai nt Thinner
Mixture
Ref. A s p e r
S uppl i er
n
R e c c o m m a d a t i o
B e a k e r &
2 0 L C a n
4 No c ont ami nati on -
B y In P r o c es s E ve r y 1 0 0 % filter
F i l l i ng
N o n e vi s ual Ins pec t i on
*In c a s e operat or fi nds a n y abnorm al i t y t o b e
out of s p e c , t hen h e i m m e d i at e l y n e e d s
i nform A r e a i nc harge.
0 1 1
P a i nt M i xi ng
Tank , F ord
W a t c h , To p c oa t 3
P ai nt ,Thi nner
2 2 5 P ai nt M i x i ng C u p , S t o p
No. Product Proce ss Specification Measurement
Tolerences Techniques
M e a s u ri n g b y
o n c e E ve r y H o u r ----- o n c e / m o n t h
1. V i s c os i t y t esti ng of
1. vi s ual c h e c ki n g a n d rec ordi ng of
Ref. V i s c os i t y V s F or d C u p B 4 i n c o m i n g pai nt b y Q C
pai nt vi s c os i t y b y pai nt k i t c hen
T e m p . gr a p h M e a s u ri n g b y
o n c e E ve r y H o u r ----- o n c e / m o n t h
i nc harge before i s s ue of
operat or i n pai nt
T h e r m o m e t er t he s a m e b a t c h f r o m
vi s c os i t y c h e c k s he e t (P / PA /M /F-
s t ores o n l i ne a n d
M e a s u ri n g b y rec ordi ng of s a m e i n
2. Qual i t y i ns pec t i on b y Q C
o n c e E ve r y H o u r ----- o n c e / m o n t h i n c o m i n g m at eri al
i nc harge for pai nt vi s c os i t y duri ng
c h e c k sh e et ( P P A M - F 0 -
p r o c e s s audi t P / P A / CQ/ F - 00 2
0 4 0 )
Part/ Process Name/
Machine, Device,
Process Operation
Jig,Tools for Mfg.
No. description
Control Method
Reaction Plan including corrective action
Spe cia l
characteristics
Product/ Process Evaluation
Da te
Sa m ple Size
Operator
Size Freq.
Sample Size Inspector
Part Name/Description. : 1. G91 CABIN (SLEEPER AND DAY)
2. BOSS CABIN
Supplier Plant : Supplier Code :
Supplier Plant Approval Date : Customer Quality Approval
Other Approval Date (If Required) : Other Approval Date (If Required) :
Characteristic Methods
Date : 18.12.13
P a r t N o . / L a t e st c h a n g e L e v e l : 1. B 0 Y 0 0 6 0 1 / B 0 Y 0 0 8 0 1
2. B 0 Y 1 7 7 0 1
Co re T e a m : Ro h i t, De e pak, La khvi nd er Ka u r,Rish i, Ajay,Mukesh , S hiv Customer Engineering Approval Date (If Required) : Prepared By(CFT) Checked By(BU)
P u j an,Aksh ansh ,Joy Gu r u Prepared By(CFT) Checked By(UP)
C O N T R O L P L AN
Prototype Key Contact/Phone :05944-259163 Date (Origin) :1/03/2011 Control Plan Number : P/PA/M/C/035 (PAINT KITCHEN)
Revision Number : 000
4
5
6

Step 7- Conclusion
 Benchmarked Gloss Level achieved from baseline 92 % to 95 %.
 Smooth, Glossy ( Paint Exterior appearance).
 Customer delight & attractive Quality
 Awarded by CV of the year.
 Sales Volume increased YOY from FY’14 (1081nos.) to FY’16 (2102 nos.) by 51%.

Boss Customer Assessment-
Positive

Horizontal Deployment
Boss :
Plastics parts • M/s TACO @ PNR
Captain Cabs
U-Truck Cabs

Gloss Boss cab Paint,25.08.16.pptx

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Gloss Boss cab Paint,25.08.16.pptx