PROJECT REPORT

ON

FPM PAINT DEFECTS AND COST EFFECTIVE PAINTING

SUBMITTED BY-

OBJECTIVE
To identify the areas of concern in the painting process To observe the methodology of the process and make a note of the deviations from the ideal paint process, if any. To keep a track on the processes such as : Loading unloading of components Drying curing operations Quality of paint primers bought by the company Quality of priming done by vendors , e.g. in boom. which conduce to faults per machine paint. Make Paretos chart for boom and main frame.

PAINT DEFECTS
Paint problems include a wide range of defects that can be found before or after painting. To maintain the quality and satisfy customers, we must be able to analyze and correct finished products efficiently. The defects may arise due to widely varying reasons including manual errors, machining errors, handling errors. Ideally, every vehicle can be released to the customer after paint baking and a minor clean-up. Regretfully, even the best, most professional painting processes will encounter minor paint flaws that must be fixed.

LIST OF PAINTING DEFECTS

Paint color mismatch Orange Peel Runs and Sags Paint fish eyes Water spotting Peeling Paint cracking Rust under the finish Curing failure Bleeding Blushing Blistering

DEFECT ANALYSIS
PAINT COLOUR MISMATCH A paint colour mismatch causes a repair area to look a different colour than the original colour of the vehicle. The value (lightness or darkness), hue (colour,cast or tint) or chroma (cleanliness, grayness or muddiness) may not be exactly the same in the two paints. CAUSES: There are several reasons for a paint colour mismatch. The most common causes of a colour difference include improper mixing and not spraying the paint properly.
PREVENTION: To prevent a colour mismatch always use spray-out test panels and let-down test panels.Use a spray-out panel with two stage. CORRECTION: To correct a paint colour mismatch you must repaint the area. You might have to tint the paint a slightly different colour or use different spraying technique.

ORANGE PEEL
Orange peel is an uneven surface formation, much like that of an orange. When viewed under a magnifying lens, the paint surface looks rough, bumpy and textured. Orange peel is caused by poor fusion of atomized paint droplets. Paint droplets dry out before they can flow out and level smoothly together. CAUSES: Improper gun adjustments and spraying techniques often cause orange peel. Too little air pressure, wide fan pattern and spraying at extensive gun distances cause droplets to become too dry during their travel time to the work surface. Improper adjustments does not let the paint flow smoothly. PREVENTION: Use proper gun adjustments, techniques and air pressure. Allow proper flash time and dry time. Do not dry by fanning. CORRECTION: Two full wet coats of clear, proper applied with the corrected flash times between each coat will normally correct orange peel problem.

RUNS AND SAGS

Paint runs occurs when gravity produces a mass slippage of an overwet and thick paint film. The weight of the uncured paint causes it to slide down the surface.. A paint sag is a partial slippage of the paint created by the film that is too heavy to support itself.
CAUSES: Applying too much paint in one place. Not allowing enough flash time between coats. Low air pressure causing lack of atomization. PREVENTION: Use proper spray gun motion, distance and speed. Select the proper thinner/reducer. Use proper air pressure. CORRECTION: On a small area of wet paint, you can use solvent to wash off the run or sag before repainting. If the run is on a large panel allow the paint to dry enough for wet sanding.

PAINT FISH EYES

Paint eyes are small dimples that form in the liquid paint film right after spraying. If watched closely when forming the paint will actually flow up and out of the small dimple or crater.

CAUSES: Fish eyes are caused by improper body surface cleaning or preparation. Presence of silicon in polishes. Containment of shop air lines or hoses.
PREVENTION: Do not touch the paint surface with anything that could have silicon or any other contaminant on it. Wear clean gloves when touching body surfaces. CORRECTION: Mix in small quantity of fish eye eliminator additive with the paint. If area cures too much then allow the paint to cure or dry.

PAINT CRACKING
Paint cracking is a series of deep cracks resembling mud cracks in a dry pond or lake bed. Often taking the form of three legged stars in no definite pattern. CAUSES: Excessive film thickness. Extensively thick topcoats magnify normal stress ad strains that can result in cracking even under normal conditions. PREVENTION: Do not pile on topcoats, Allow sufficient flash and drying times. Do not dry by gun fanning. Thoroughly clean all areas that will be painted before sanding. Be sure that the surface is completely dry before applying any coat. CORRECTION: Remove clearcoat and colourcoat down to the sealer or the primer and apply new coats.

WATER SPOTTING
Water spotting is the general dulling of gloss in spots or masses of spots. CAUSES: Water evaporation on the finish before it is thoroughly dry. Washing the finish in bright light. PREVENTION: Do not apply water to a fresh paint job and try keep a newly finished vehicle out of rain and snow. Allow sufficient drying time before delivering the vehicle to the customer. CORRECTION: Compound or polish the vehicle with rubbing or polishing compound. In severe cases sand the affected areas and refinish.

CURING/DRYING FAILURE
A curing /drying failure is the abnormally slow hardening of a refinished product. The material remains wet or soft for a prolonged period of time. This might involve a body filler, spot putty, primer, sealer, paint, or corrosion protection material. CAUSES: Improper stirring or mixing of product ingredients. Sloppy surface cleaning and preparation, allowing chemical contamination to refinish materials. Wet sanding with contaminated water.

PREVENTION: Thoroughly clean all areas to be repaired with a wax and grease remover to avoid chemical contamination. Finger knead(mix) cream hardener for spot putty and body filler.
CORRECTION: Wash or sand all affected areas thoroughly as needed and refinish.

BLISTERING
Blistering shows up as small, swelled areas on the finish that look like a water blister on human skin. There will be a lack of gloss if blisters are small. You will find broken edged craters if the blisters have burst.
CAUSES Improper surface cleaning or preparation. Use of the wrong thinner or reducer, such as using a fast-dry thinner or reducer, especially when the materials is sprayed too dry or at an excessive pressure. Excessive film thickness. PREVENTION Thoroughly clean areas to be painted before sanding. Select the thinner or reducer most suitable for existing shop condition. Allow proper drying time for prime-coats and top-coats. CORRECTION If damage is extensive and severe the paint must be removed down to prime-coat or metal, depending on the depth of the blisters.

RUST UNER THE FINISH

Rust under the finish will show up as raised surface spots or peeling or blistering in the paint. In the instance, rusting steel had oxidized, started to flake, and pushed the paint upwards and away fro the body. CAUSED: Poor corrosion protection or forgetting to apply weld through and self-etch primer is the main reason for rusting. Broken paint film allows moisture to creep under the surrounding finish. PREVENTION: Wear plastic or rubber gloves when touching the body surfaces. Apply all corrosion protection materials according to the vehicle recommendation. CORRECTION: Seal off possible entrance points for moisture fro the inner part of panel. Sand down to bare metal, prepare the metal and treat it with phosphate before refinishing.

CONCLUSION
After studing the various painting defects in the liftall department we were given the task to minimize the defects and suggest alternative ways to provide cost effective painting. We have used the principle of Paretos chart in order to start the improvement process in the most efficient way. It provides a prioritization tool so that process improvement activities can be organized to get maximum benefit with least effort.

70 60 Number of defects 50 40

30
20 10 0 -10 -20 dirt in paint sag orange peel thin paint sealer under scratch

Here we have laid down defects that are predominant in decreasing order.

Cumulative percent 100

120

20

60

80

40

THANK YOU