1. PAINT SHOP
PROJECT
How to make the Paint Shop dust free.
"Paint is not just about color. The
paint also protects the body."
Group members:
Ramsha Islam - NUST - Industrial & Manufacturing
Muhammad Nabeel Khalid - NUST – Mechanical
Raffay Bin Rauf - NED - Industrial & Manufacturing
Shahbaz Baig - NED - Industrial & Manufacturing
2. Usage of Lacquer and Thinner
(Fuel Tank)
1st coat, 207
2nd coat,
62
3rd coat,
31
Other, 93
Total: 424 Coats
The information obtained on 27th June, 2012
3. Wastage of Lacquer and Thinner
(Fuel Tank)
The information obtained on 27th June, 2012:
Amount of thinner + lacquer= 20 – 24 liters (average 22liters).
OUR EVALUATIONS:
424 coats with 22,000ml
Per coat= 51.89ml
300 coats= 15567ml
93 coats= 4825.5ml
31 coats= 1608.5 ml
WASTAGE:
4825.5 + 1608.5 = 6434ml
(6434/ 22000) x 100= 29.25%
4. Time Consumption
(Fuel Tank)
The information provided on 27th June, 2012
It takes 2 hours to complete a cycle and on its completion 120
fuel tanks are finished.
OUR EVALUATION
1 tank in 1 minute
93 + 31 tanks were re-lacquered = 2 hours 4 minutes!
TIME WASTED:
124 fuel tanks could have been finished
in that time!
5. Usage of Paint
(ABS parts)
Painted
Once, 555
Repainted,
35
Total: 590
The information obtained on 27th June, 2012
6. Wastage of Paint
(ABS parts)
The information obtained on 27th June, 2012:
Amount of paint+ thinner+ hardener used on 65 parts: 7 liters
OUR EVALUATIONS:
Per part = 107.7ml
590 parts= 63.54 L
35 parts= 3.7 L
Total= 67.24 L
WASTAGE:
(3.7/ 67.24)x 100= 5.5%
7. Time Consumption
(ABS parts)
The information provided on 27th June, 2012
It takes 90 minutes to complete 150 parts (L and R side
panel).
OUR EVALUATION:
36 seconds per part
21 minutes for 35 parts
TIME WASTED:
21 minutes!!
8. Sources of Contamination
1. Facilities
• Walls, floors and ceiling
• Fans (Ceiling, exhaust and bracket)
• Conveyor
• Trolleys
2. People
• Skin flakes and oil
• Clothing debris (lint, fibers, etc)
• Hair
3. Tool Generated
• Brooms, mops and dusters
• Friction Particles (Sand paper)
9. Instant Measures
Put plastic curtains on
the gates.
Workers should wipe
there shoes before
entering.
For that place a wet
and a dry mat at the
entrances.
10. Proposed Solution
Upon arrival to the
Paint shop, dust
or any impurities
can ruin a paint
job.
Personnel that
enter the Paint
Shop must wear
special suits and
headgear to
prevent unwanted
particles from
entering the Paint
Shop.
11. Proposed Solution
Then while wearing the Paint Suits, they are re-
cleaned by being “blown and vacuumed” in a
“Clean Room” before entering the Paint Shop.
This removes any loose dust or particles that could
potentially contaminate the Paint Shop
13. Cleanroom
A cleanroom is defined by ISO14644-1 as a room
in which the concentration of airborne particles is
controlled and in which other relevant parameters,
e.g.
1. Temperature
2. Humidity
3. Pressure, are controlled as necessary.
14. Ventilation
Ventilating is the process of "changing" or replacing air in any
space to control:
1. Temperature
2. Remove moisture
3. Odors
4. Smoke
5. Heat
6. Dust
7. Carbon dioxide
8. Replenish oxygen.
Ventilation includes both the exchange of air to the outside as
well as circulation of air within the building.
15. Proposed Solution
As we have discussed that moister control or
humidity is also very important for dust control.
60 – 70% of the fuel tanks are re-lacquered in the
dry months. (November, December, January and
February)
To control that we can add humidifier and
dehumidifiers which control the misture content in
the air accordingly.
18. Air Shower
Clean Room Air Showers serve to protect clean
room environment from unwanted contamination.
Air showers can greatly enhance a clean room's
performance by removing surface contamination
from clothing and clean room garments.
Gowning/changing room areas are the interface
between a dirty "street clothes" environment and a
clean room environment.
Air showers blow off and remove much of this
contamination preventing it from entering the clean
space.
