paint shop project (1)

PAINT SHOP PROJECTHow 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 & ManufacturingShahbaz Baig - NED - Industrial & Manufacturing

Usage of Lacquer and Thinner(Fuel Tank)

1st coat; 207

2nd coat; 62

3rd coat; 31

Total: 424 Coats

The information obtained on 27th June, 2012

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%

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!

Usage of Paint(ABS parts)

Painted Once; 555

Repainted; 35

Total: 590

The information obtained on 27th June, 2012

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%

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!!

Sources of Contamination1. 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)

Instant MeasuresPut plastic curtains

on the gates.Workers should

wipe there shoes before entering.

For that place a wet and a dry mat at the entrances.

Proposed SolutionUpon 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.

Proposed SolutionThen 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

Proposed SolutionSoft Wall Clean rooms

CleanroomA 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. Temperature2. Humidity3. Pressure, are controlled as necessary.

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.

Proposed SolutionAs 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.

Proposed SolutionHumidifier and Dehumidifier

Proposed SolutionAir shower pass through doors

Air ShowerClean 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.

Proposed Layout