KIN RAILWAY EQUIPMENT PVT LTD
Powder coating Process Improvement action plan
Date/Month – 15-04-2024
Agenda –
 Powder Coating process Monthly RFT trend
 Root cause analysis (Fishbone, FTA, Why-Why)
 Corrective & Preventive Action plan
Powder coating process Monthly RFT Trend - Apr-23 to Apr-24
Month
Apr-23
May-23
Jun-23
Jul-23
Aug-23
Sep-23
Oct-23
Nov-23
Dec-23
Jan-24
Feb-24
Mar-24
Apr-24
Total Produced Part
6558
6883
3642
3081
4181
3652
3433
3141
3784
2266
2675
3263
3227
Direct OK
5360
6257
3433
2776
3933
3428
3187
2824
3391
1478
1938
1627
2215
RFT
82%
91%
94%
90%
94%
94%
93%
90%
90%
65%
72%
50%
69%
100%
91%
94%
94%
90%
94%
93%
90%
90%
90%
Till 12-04-2024
82%
80%
72%
RFT %
70%
69%
65%
60%
50%
50%
40%
30%
20%
10%
0%
Apr-23
May-23
Jun-23
Jul-23
Aug-23
Sep-23
Oct-23
Nov-23
Dec-23
Jan-24
Feb-24
Mar-24
Apr-24
Defect Photos
Crater
Dust
Lint
Fish Bone analysis
MACHINE
MANPOWER
-Powder coating gun
contamination
-Powder coating booth
contamination
-
MOTHER NATURE
-Wrong parameter setting in
machine
-Part surface preparation not done
properly
- Improper Powder application by
the Operator
-
- Raw material
contamination
- Powder contamination
-
MATERIAL
METHOD
-Booth Temp & Humidity not maintained
-Part dew point not maintained
-
- Improper storage of Powders
- Expiry Powder application
- Improper Earthing
- Contamination in the Air line
- Passivation chemical properties not
maintained
-
Problem
– Crater,
Dust &
Lint
FACTOR TREE ANALYSIS (FTA)
JUDGEMENT
5M
+ Envirt
Machine
FACTOR
Potential
Causes
Powder coating gun
contamination
Powder coating booth
Machine
contamination
Man
CONTROL
POINT
Daily Gun cleaning
STD
Applicable?
STD
respected?
Link
with
Pb?
Gun completely cleaned and trail taken
YES
YES
NO
New spray gun machine procured and trail taken
YES
YES
NO
Trail taken with Out source supplier Spray Gun
YES
YES
NO
Booth inside completely cleaned and powder coating trail
taken
YES
YES
YES
Crater Observed
Trail taken in New Powder coating booth (Near to Old
booth)
YES
YES
YES
Crater Observed
Validation of the Cause
Daily Booth Cleaning
Wrong parameter setting in
Spray gun machine
Defined Program No
Parameter checked and found as per WI
YES
YES
NO
Part surface preparation not
done properly
As per WI
Part surface preparation done as per WI
YES
YES
NO
Powder application validated and found Ok
YES
YES
NO
Trail taken with 3rd party Operators
YES
YES
NO
Temperature maintained As per DTRF Requirement
YES
YES
NO
Humidity maintained As per DTRF Requirement
YES
YES
NO
Dew point of the part verified and found OK
YES
YES
NO
Trail taken with Out source supplier booth
YES
YES
NO
Improper powder application by As per WI
Operator
As per WI
Booth Temperature not
maintained
SELECTED CAUSES
As per DTRF
Mother
Booth Humidity not maintained As per DTRF
Nature
As per Dew point table
Part dew point not maintained
As per Dew point table
FACTOR TREE ANALYSIS (FTA)
5M
+ Envirt
JUDGEMENT
FACTOR
Potential
Causes
Raw material contamination
CONTROL
POINT
Supplier MTC
Material
Quality issues in the Powder
material
Method
Validation of the Cause
STD
respected?
Link
with
Pb?
Raw material TC Verified, Chemical and Mechanical
properties found OK
YES
YES
NO
In PML3 RAL 9003 powder (Batch no – Q0D3304050)
using time Crater started
YES
NO
YES
Craters observed in-house
Powder coating trail taken at AkzoNobel supplier end
YES
NO
YES
Craters observed on Akzo
lab
Supplier Test reports
Improper storage of Powders
Shelf life store room
Temp & Humid controlled areas Powders are stored
YES
YES
NO
Expired Powder used
As per Shelf life std
Powder Expiry date verified and found OK
YES
YES
NO
Improper Earthing
As per WI
Earthing verified and found OK
YES
YES
NO
YES
YES
NO
YES
YES
NO
YES
YES
NO
Contamination in Air line (Oil) Passivation chemical properties
not maintained
SELECTED CAUSES
STD
Applicable?
As per PT WI
New Air compressor with filtration system installed and
checked
All the Chemical properties checked in Outsourcing lab, and
result found Ok
Made fresh Bath chemicals and trail taken
WHY-WHYs to find the ROOT cause for OCCURRENCE
SELECTED CAUSE:
(selected from the FTA) - Air contamination in the Powder coating Booth
st
1 WHY:
Craters/dust observed on the part due to Airborne contamination
2
nd
rd
WHY:
- High PM (More than 50mics) dust particles present in the atmospheric air
3 WHY:
- PML3 Project RAL 9003 Powder residues spread all over the booth (Above the roof fall
ceilings) which is caused the Airborne contamination
DOE @ KIN , Coimbatore
S.no Design of experiments
Location
Powder supplier Powder grade
Gloss
Powder batch Observation
Remarks
1
Regular process at KIN (as per WI)
KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3304050 Crater observed
New batch powder
2
Trail at 3rd part supplier 1
Coimbatore
Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3304050 Crater & Dust observed New batch powder
3
Trail at 3rd part supplier 2
Mysore
Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3304050 Crater & Dust observed New batch powder
4
Trail 1 - Increased DFT
KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3304050 Crater observed
New batch powder
5
Trail 2 - Reduced DFT
KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3304050 Crater observed
New batch powder
6
Trail 3 - Without Chemical treatment
KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3304050 Crater observed
New batch powder
7
Trail 4 -Outside powder application
KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3304050 Crater observed
New batch powder
8
Trail 5 -Booth off condition application
KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3304050 Crater observed
New batch powder
9
Trail 6 -3in 1 chemical used before powder app. KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3304050 Crater observed
New batch powder
10
Regular process at KIN (as per WI)
KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3173013 No defects
Old batch powder
11
Regular process at KIN (as per WI)
KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) Q0D3354006 Crater observed
New batch powder (after batch no #050)
12
Regular process at KIN (as per WI)
KIN,Coimbatore Akzonoble india RAL 9003-Interpon Satin (55~65) QOD4072017 No defects
New batch powder (after batch no #006)-Currently at usage
Legend : [ N-No crater & Dust ] [ C - Crater ] [ D - Dust ] [ C&D - Crater & Dust ]
Powder application trail details at different locations
Month
Jan-24
Feb-24
Mar-24
Project
Powder Name
KIN
Sup.1
Sup.2
KIN
Sup.1
Sup.2
KIN
Sup.1
Sup.2
ML3
NCSS1602-Y64RGS
N
-
-
C
D
-
C&D
D
-
PML3
RAL 9003 (Q0D3304050)
C
C
-
C
-
C
-
-
-
PML3
RAL 9003 (Q0D3354006)
-
-
-
C
-
-
C
-
-
PML3
RAL 9003 (QOD4072017)
-
-
-
-
-
-
N
-
-
CORRECTIVE & PREVENTIVE ACTIONS PLAN
Sl.No
ACTIONS TO ERADICATE OCCURRENCE
Responsible
Target
date
Actual
date
Status
1
Entire booth and its environment need to be cleaned
(Ref next slide for time plan)
Kalai
Ref next slide
In-progress
2
Part preparation will be done in separate isolated room
Kalai
20-04-2024
In-progress
3
Water dry off oven will be added after chemical treatment
Arun
28-05-2024
Open
4
Enclosure will be provided for new powder coating booth
Arun
June-24
Open
5
Powder booth entry & exit areas air curtain will be installed
Arun
June-24
Open
Arun
June-24
Open
Kalai
June-24
Open
6
7
Real time monitoring of dust particles in air will be equipped
with powder spray booth
Out source supplier will be developed and qualified for AT
powder coating requirements as a contingency action
Powder coating Booth PLM activity Time plan
Paint shop cleaning schedule
Si.no
Plan
Activity description
Completed
Pending
Start date End date
Status
Completed
Resp 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1
Roof ceiling removal
22.3.24
24.3.24
Arun
2
Ceiling structure removal
17.4.24
17.4.24
Arun
3
Duct insulation removal
17.4.24
17.4.24
Arun
4
Hanging rods removal
17.4.24
18.4.24
Arun
5
Duct removal (No impact for prod.)
19.4.24
21.4.24
Arun
6
Oven floor polishing
19.3.24
20.3.24
Arun
6
Lighting installation (No impact for prod.)
17.4.24
22.4.24
Arun
7
Conventional booth to oven enclosure fixation
18.4.24
21.4.24
Arun
8
Paint equipments outside deep cleaning
17.4.24
19.4.24
Kalai
9
Fine dust removal inside equipment's
20.4.24
20.4.24
Kalai
10
Production trail
20.4.24
20.4.24
Kalai
11
Continuous production
21.4.24
-
Kalai