I am working on a project 'dent per car reduction', to reduce the dents which are present on the body after Electro Deposition (paint shop).
The car body which comes after ED has small craters/depressions called dents. Sanding and buffing are performed to remove the dents. The aim is to reduce dents and also to keep the area of ED coat removed during buffing and sanding as minimum as possible, to reduce cost and time in coating the repaired area again.
I welcome all suggestions/ideas which can help.
Hello Tarun
please specify you are talking about dents or craters? My understanding dent is caused by external impact but crater can be caused by other phenomena.
If it is dent is much more easy...check the process to find the root cause where is caused
If it is crater can be caused by for example oil contamination, ripple of rectfier, different sheet metal substrate, high voltage, bath composition and several others
I hope I could help
its better for you to go ahead in this problem with Six sigma approcah. wrote down the each and every (Even Silly) possible causes for the dents. then do funneling of the cuses and then you will reach to one or more route causes of the problem. one solution is found for route cause, implement proper control measures on the solution adviced. This approcah will clear you through the problem.
you can write possible causes as
1. dust in paint
2. dust in paint gun.
3. dust in storage area or drying area....etc....
@Paulo- I've specifically mentioned both dents and craters because the project aims at reduction of both, the ones caused due to external impacts and those caused by all the other reasons possible. Please let me know what all measures I can take as an intern to improve the process.
@Usman- Thanks for your suggestion. This would help
Crater is mainly due to diferent surface tension.
Can be caused by :
ripple of rectifier ( no more than 5%)
Oil presence on steel or baths
P/L ratio
Diferent steel substracte (galvanized or other's?)
Lack of bath additives to decrease surface tension
Dents
please check step by step your process
This issue is easy to solve
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