working together: a success story

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WORKING TOGETHER: A SUCCESS STORY Anthony Lynn Morton Metalcraft Morton, Illinois 309-673-2224 - 89 -

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WORKING TOGETHER: A SUCCESS STORY

Anthony Lynn Morton Metalcraft

Morton, Illinois 309-673-2224

- 89 -

?fANUFACTURING QUALITY PLAN FOR FINISH PAINT PROCESS

i. j :

- 90 -

MANUFACTURING QUALITY

FINISH

FOR

P L A N

PAINT PROCESS

- 91 -

CERTIFICATION TFAM

QUALITY:

PURCHASING:

FINISHING:

CUSTOMER FEEDBACK:

QUALITY:

PLANT MGR.:

- 92 -

QUALITY ASSURANCE MANAGER :

PURCHASING MANAGER:

V. P. ENGINEERING:

APPROVALS:

SOURCE PLANT MANAGEMENT

PRESIDENT & CEO:

V. P. MANUFACTURING:

PLANT MANAGER:

- 93 -

FEEDBACK

I n t h e event oE a non-conformmce found by t h e Pa in t mpdrtme-t,

i n t e r n a l auditor or customer, the 'hnufacturinq Qual. i ty P lan -.:ill.

k~ reviewed by t he Pa in t DepartmnL f o r vea'tncss or l a c k of a5-

herencc and a ? x o p r i a t e ?ction t3':zq t o Frsvent recux-ence.

Pa in t Department \ r i l l i n i t i a t e an3 implemant im?rovemmt t o t+

Plan as of t en 3s circumstances fiic73te an3 v i11 providz revisims

t o t h e Manufacturing Qua l i ty Plail 3s nez3ed.

\ r i l l maintain a l l t he au5iits 373 ?,=-rtiw,rlt inEormation obt?in?S

an:! male ava i la31e t o Qua l i ty Asswznce 3n an as-nee523 k a s i s .

T h i fol1o:ain; s i y n i f i c a q t char?ct?ristir:s determinod 'TI' t'72

c u s t o m r an3 a u d i t t 2 3 m rill te mexure? for r eWr t i r , 2 zonform-

ance o r control.

71s

The P a i n t &?artrent

PAINT GLOSS PAINT MIL TIiTCX3ESS ?AINT HARDh'ESS

- 94 -

...

:: "..

LAYOUT + OPERATIONS

- 95 -

?

I

I I I I I

I i I ! I ' 9

. e

. *

T

i I

. . J

J'

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. .‘

., .

2ND STAGE 3RD STAGE IST STAGE

18 f t . spray 1 2 f t . spr3y

2700 y l l o n s 1500 Tallons

Cl?an:?r - ?hosphate Clear watsr

C o n c a t r a t i o n - 3.5% -

Timp. - 130 dq rees Ambient

2H Ran;? - 5.0-5.7 7 .0 t o 8.0

Wash Time, 90 s=c/max 4 5 sec/max

13 ft. spray

1500 731lons

Clesr WQter

-

Ambizit

7.0 to 8 .0

4s s2c/m3’:

*

** A f i r ia l D . I . is 3v:’tila’sla a t the? end of s t a g s 3 .

T h x z is a clear mter rinse betveln each of the s t a y s .

Lino sne& - 5 f t . min. t o 20 f t . ma::. 5:Cpm:iin2 on ?i?ce p a r t s .

Subs t ra t2s - C d d r o l l , hot r o l l , plvansalcf i , aluminum.

3 ) Dry O f f Oven

a ) 65 foot 33s f i r z d .

b)

c) 6 -

d )

4 ) 2 Tur!3ine Di.;cs - E l e c t r o s t a t i c

250 3egraes t o 400 dqress tempzrature

t o 3 m i n . depending on l i n ? speed 10/20 a v 2 r q c .

Cool t o hot a t t i m e o€ app l i ca t ion . (Matzrial thickness)

- 97 -

w

5) P r e Touch-Up Booth (Dedicated Lines)

6 ) 2 Post Touc’n-Up Booths - Dry Booths

a ) 3 s l e c t r o s t a t i c a i r spray guns

b) 10, 5, 3 , 2 g a l . p ressure pots

c) I n l i n e for touch-up (guns)

d ) 3 e l e c t r o s t a t i c a i r spray guns (dedicated l i n e s )

Bake Oven Conveyorized 170 fezt

a ) Gas-fired

b) Time i n oven, 8 - min. t o 34 minutes

c) Terperzture 310 d q r c e s - 330 dsgrees averaqo

7)

MATERIALS

1) Conventionzl so lvent

2 ) High - solids enamel

3 ) Epoxies

4 ) P lu ra l comyment

5) Polyurethane

SOLVENTS

1) Xylene (redwe - u s 2 a s clean-up th inne r )

2 ) Butyl - D i o s i t a l

3 ) Lacquer th inner

vIscosITY

Drum 40 to 60 SEC $3

Applicat ion i-isc. 18 t o 50 #3

I n l i n e ?airit heat?r - 77 3eTreFs t o 130 cle2r?es

- 98 -

STRIPPER

900 gallon enamel hot strip

190 degrees to 200 degrees

BURR OFF OVEN

800 degrees

Tvo hour cycle

High pressure - hose to clean racks

SIZE LIMITATIONS FOR SYSTEM

1) 5' H. X 10' L. X 36" D.

2 ) .375 to 1.00 material thickness for oven dry as cure out is

PAINI' SUFPLIER - NAME

1)

2 )

3 )

4)

KEY SOURCES

- 100 -

SPEC - #

PROD *

CITY

SUPPORT PROGRAM

T h i s section provides a brief description and overview o€ the su?zort

activity that assures a quality product and the department responsible

for administering each program.

MAINTENANCE PROGRAM

Preventative maintenance programs provide scheduled maintenance as

required by equipment suppliers or previously established time tables

Th2se programs are performed weekly by m2ans of a maintenance sche-

dule check sheet. The Paint Department is responsible for this

:ogram.

MAINTENANCE SCHEDULE P A I N T DATE

0. K. - .. CONVEYOR R E P A I R NOTES

L i n e Brushes I d l e r s Bear ings Amp Readin9 Mo to r Tension L i n e S t raos Chain & R o l l e r s L i n e Lube

WASHER

(1 ) A i r Seals ( 2 ) Spray Nozzles

b Pipes (3) C e i l i n g s 8 W a l i s (i) G r a t i n g s ( 5 ) Gauges (6) Conveyor L i n e

R a i l Wear ( 7 ) ~ i n e Cover

ORY OFF

( i ) A i r Seals ( 2 ) Gauges ( 3 ) D e f l e c t o r s ( 4 ) Exhaust (5) F l o o r i n g

RANSBURG

R E P A I R XOTES

O.K. - R E P A I 2

O . K . - NOTES - REPA I R

r . r 11 t e r s i ' o o r F i l t e r s A i r 6 3rain R e c i p r i c a t o r C a b l e s I d l e r s Gauges V o l t a g e C e i l i n g & Wal ls L i g h t s Pump & L ines

NOTES AIR MAKEUP

(1) F i l t e r s ( 2 ) Heat

R E P A I R

NOTE5 STACKS IN BOOTHS REPA I R

(1 ) Fdn ( 2 ) W a l l s & C e i l i n o s

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. '

DATE MAINTENANCE SCHEDULE PAI:;T

NOTES O.K. REPAIR - iOUCii UP BOOTHS

Lights F i 1 t e r Frames Cei l ings F i l t e r Grids Exhaust Fan Gauges Heater Pump F i l t e r s I n Line Floors & Walls Guns a P o t s

i

O.K. EE?AI i? - Overneaa Exnausc Air Seaiz 3ef 1ec:c.j Floor h c : s i a l l s b Ceii in?s Searings h t s i d e r c o d Gauges Conveyor l i n e S n a f t

5:z:- TA>!K

i l ) Hoist ( 2 ) Cables

2 ) Gratin? F l o o r

( 5 ) Elements : E j tacks 5 Z ~ S K ~ ' . : ( i j Hose

SEBL2R

! 1 ) Pumo System ( 2 ) Be l t s ( 3 ) Buckets ( 4 ) Floor 5 Area ( 5 ) Media ( 6 ) Drip Pans

- O.K. EEPAIR - I

PUEN OVEN

(1: Floor ( 2 : Walls ( 3 ) Nozzles

R E P A I R SCTES i

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‘5AUG5 AND EQUI TENT PR0GR.W

: I ? -. i j n t D 2 J q r t m 2 n t em;sloys var ious chx’ciii7 : ~ U ~ P S i n the f i n i s h

-mint procz?ss t3 assur? conformity to s z x i f i c a t i o n s and t o provide

ziistomzr s a t i s f a c t i o n .

c a l i 3 r a t i n i an3 r e?a i r ing , i f necessary, t’ie c”lc!c gau3es. G a u p

a d equipmsnt t e s t i n g is don2 in-house ‘ ~ y c’?eckin-; aga ins t s tandards

s 2 t for equipment c a l i b r 3 t i o n .

rcsbsmsihl? for this p royam.

The l i n e organizat ion is respons ib le €or

The Quality Assurance Denartment is

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I

I

GAUGE & EQUIPMENT

--

DATE ITEM

INSPECTION & VERIFICATION

PASS - FAIL INSPECTED BY

- 106 -

NATERIAL TESTING PROLT3AM

m lhe compan!. re?:.ii rz.; i ts su?:Jliers t o c e r t i f y t h a t t’izir oroducts

mzet or e ~ c s e d custo?x reyiremmts. SupFlizrs 1.Jho a r e c u s t o n x

a??rovecl, mus t a l s o c s r t i f y t?ieir a 3 i l i t y t o meot customzr s p c i -

f i c a t i o n s .

t h i s program.

T h e QJ3l:zy Assur.l?nce Dzpartment is responsible for

PAINT TEST PROGRAM

The com:mny rquir2s 3 sample -p11on of mats r ia l from a su?Aie r of

oiir chozsing 3r one :;.-a is customzr 3r)provsd.

s>rayecl OH a t z s t par.21 05 our stszl and tested for conformanc? t o

customsr s?zcificati::-.

13 3allon t r i a l run t-l Yrocess on-linz v i t h Yiece ?arts.

D p p r t m n t is respns1’312 f o r t h i s ?roJram.

This sam2le g a l l o n i s

A f t i r i n i t i a l t z s t i n g , we xi11 as’: fo r P

The P3i t - t

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PAINT TEST REPORT

DATE :

PAINT # :

SUPPLIER:

VISCOSITY: ZAHN:

PAINT TEMP: (AMBIENT) TIME OF APPLICATION

REDUCED: YES NO

XYLENE: B.D. L.T.

VISCOSITY: ZAHN :

LINE SPEED:

BAKE TEMP.:

FILM THICKNESS:

SHEEN:

CROSS HATCH:

HARDNESS :

RECOATABILITY:

STRIPABILITY:

SANDABILITY:

TACKABILITY:

RECOAT :

APPROVED FOR TRIAL RUN:

OPERATOR:

DATE :

YES NO

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ASSESSMENT AND CONEQRWlNCE AUDITING PROGRAM

By way of a u d i t s , both d a i l y and wee'ily, a monitoring device is

provided t o pinpoint; problems to enable corrective ac t ion t o make

necessary adjustnlents to the process. The P a i n t Department is re-

CONTROL CHART

PRODUCT FLOW

STAGE I I LOAD 1

WASH

DRY 1 PLUG & MASK

I

PRE-TOUCH

DISC

POST-TOUCH 1 -~

I BAKE

UNLOAD

I = Visual Inspect M = Measure CC = Control Chart

- ACC = Auto

I

I

C.C., I,

I

I

I

M. I.

I

ACC, M.

ACC

M, I

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QUALITY PLAN FINISHING DEPARTMENT

SIGNIFICANT CONTROL POINTS

P ! a t c r i a l F l o u P r o d u c t & P r o c c a s T r a c e a b i l i t y Method P r o c e a a C h a r a c t e r i s t i c a C h e c k i n g Q u a n t i t y C h e c k i n g P e r s o n n e l L Type of Record L C m t r o l P t s . C h e c k c d / M o n l t o r e d F r e q u e n c y Checked H e t h o d R e s p o n a ~ b l e R e t e n t i o n P e r i o d

V l a u a l Q u a l i t y C o n t r o l Log S b c e t S i A G E U n p a i n t e d Each U n i t Rand- H a t ' l H a n d l c r U n p l a t c d Skid P l U .

I r o n m b P a r t s A c c a p t a b l l l t y

LSAD P i e c e S k i d P i e c e V i a u a l F i n i s h i n g H a t ' l H a n d l e r P a r t . T u b s P a r t .

A c c e p t a b i l i t y L o a d e r

T i t r a t i o n Log R e p o r t

GASHIRINSE S y a t m !-cry All V i a u a l F i n i a h i n g T i t r a t i o n L a b S u p v .

S u p p l i e r T i t r a t i o n 2 hour.

2i .Y OFF/ C h a r t R c t c n t i o n Z X L DOWN Oven Temp C o n t i n u o u a Temp. C h a r t F i n i s h i n g

R e c o r d e r Lab . Supv. 1 year Temp.Iape

PLUG C MASK Required E a c h P i e c e E a c h P l e C e V i I U a l F i n i s h i n g V e r b a l P a r t s f i a i k e r P e r P r l n t

?RE-TOUCHUP R e q u i r e d E a c h P l s c e E a c h P i e c e Visual F i n i a h i n g V e r b a l P a r t . 'area- P a i n t e r

PAINTIDISC P a i n t V i s . P e r C o l o r Per C o l o r ZahnCup P a i n t e r F i n i s h D a t a P a i n t TemD. Cavae u a i n g e a c h J o b A i r Temp. Re1 . Humid.

Equip.

POST TOUCH UP R e q u i r e d E a c h P l e c e E a c h P i e c e V i a u a l F i n i a h i n g P a r t . - a r e a " wet H i l l P a i n t e r Verbal

Gauge 1 year

DAKE OVEN Oven Temp. C o n t i n u o u a Temp. C h a r t F i n i s h i n g C h a r t R e c o r d e r Lsb.SUpv. R e t e n t i o n T m p . T a p c S u p p l i e r Temp. Tape

1 year

LWLOAD F i n i a h C o l o r E a c h C o l o r Pc P a r t . P a n e l H a t c h U n l o a d e r a Log S h e e t F l l m T h i c k n c s s Each C o l o r P c P a r t . M i l Gauge Supv. V e r b a l S h e e n E a c h C o l o r P c P a r t . S h c c n C a u g e Q u a l i t y C o n t r o l Hardneaa P c P a r t . P e n c i l H d . P e n c i l C a u g e 1 year

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i I

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i - 112 -

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Ln

73

rT

r c

i

PROCESSING INSTRUCTION AND CONTROL PROGFWI

Finish Data sheets are provided at the load station of the paint

process, which in turn, controls the variables of the piece part

from start to finish.

or added changes.

is another important factor.

for this program.

Finish Data sheets are used for conformance

Our direct operator-to-operator feedback system

The Paint Departmnt is responsible

!

,

j .I !! I

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PERSONNEL TRAINING PROGRAii

Painters are certified through classroom instruction, practical

application and testing, as well 3s on the job instruction.

for all other paint personnel is Frimarily on-the-job training in

their specific areas of responsibility.

visual aids, verbal, and documented procedures.

by supervision of trained personnel.

other areas of the department provides a wider base of knowledge and

responsibility, contributing to the quality process.

mmt, as well as the Safety Department, is responsible for training in

bath the formal and informal aspect of the job.

Training

This is complimented with

Progress is monitored

Some rotation of personnel to

The Paint Dopart-

PAINTER CERTIFICATION PROGRAM

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PAINTER CERTIFICATION TEST

N A K E :

EMPLOYEE NO:

DATE:

Successful completion of this test is required in order TO become a Certified Painter. A copy of this test wi11 become a permanent part of your Personnel Employes File.

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,

?AIhTER CERTIFICATION TEST

1. Th? a i r l x e s s x z Oil Pro 3500 should be s z t a t a;3proximat?ly

what y e s s u r e ?

a. 10 - 20 1Sr. C . 40 - 60 1%~.

5. 20 - 30 lbs. d . 90 - 100 lbs.

2. Pressure t o o la;? will result i n 13oor atomizat ion which will

taus? an oranza p e l effect.

TRUE - FALSE

3. The major causs of over spray when us ing an a i r ypray gun is:

a . p rz s su re t m hiJh

b. pres su re t o 3 lor:

c. t i p too small

13. t a i l s

4. Tmpera tu re a t the hea te r is hiGher than the temperaturs a t

th2 gun.

TRUE - FALSE

5. Proper t empra5ure a t t h e gun should bE a p r o x i m a t e l y :

a . 110 - 120 C . 80 - 90

5. 150 - 180 d . makes no d i f f e rence

6. To f i n i s h p a i n t i n our system, the recommended t i p s i z e is

1.00 MN o r 1.20 MM.

TRUE - FALSE

7. *The f i n a l f i l m th ickness should be m i l s . min imum.

( a s s t a t e d i n 1E2001).

a . 2 m i l s c. 1 .5 m i l s

b. .08 m i l s d. 4 m i l s

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.. . , I . I :

. - . -- _. . .> -

8.. E l z c t r o s t a t i c spray increases the:

a . t r a n s f e r e f f i c i ency of pa in t

5. hydrau l i c pump pressures

c. tem?erature of pa in t

cl. chance of over spray

9. Hydraulic pum? cyc12 t i m should he:

a . 2 - 4 times Fer minute 2 . 1 0 - 15 tims per minute

b. 7 - 9 times per minute 3 . 20 - 30 times per minute

10. Heat providas tempratures necessary ;o reduce the v i s c o s i t y of

the 3 a i n t .

TRUE - FALSE

11. E l e c t r o s t a t i c 7a in t ing requires grour.5 s t r a p s becauss:

a. ground s t r a p s keep the t r a c t o r f r m k i n g grounrld

b . ;round s t r a p s z t t r a c t pa in t over snray

c . .2round s t r a p i provida t h s necessary ground

d . ground s t r a p s do nothin2 for pa inr ing !

12. I t is important t h a t t h e spray gun be he ld perpendicular t o

the su r face a s much a s W s s i S l e d u r i n the pa in t ing stroke.

TRUE - FALSE

13. Tain t ing s t r o k a s should 52 overlapped -'% t o bui ld t h e

r e r j u i r d f i l m i n thz l e a s t amount of sxoltes.

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15. Cure is:

a . t?ie process Sy which ?ai!it, is convzrtz5 f ron ths l i q u i d t o

the salis s t a t ?

th=l p o c z s s by 7.lk.lich ?ai*it is d r y t o tis touch b.

16. Dry q r a y is:

a. t h e form3tion 05 t i n y d r q l z t s of l i q u i 2 as i n the pa in t

spray i n 3 ?roc as s

et

su r f acz

p i i n t &icn loszs so much salvmt i n th? 2ir t 5 a t it b o c o ~ s

too d r y t o Eloir ou t r e r th2 sur f3cz

b. p a i n t f i l m rsc2din; from c e r t a i n areas of a ;3aint?d

c.

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24. Paints use at this com7any 3rc not all flamabk.

TRUE - FALSE

19. On2 way to measure paint hardness is with a pencil point.

TRUE - FALSE

20. Dry spray often results from spraying with pressure too hi3h

or from 3eincj a great distance from the work.

TRUE - FALSE

21. Orange p-"l is:

a.

h.

a paint defect charactzrized by a raised bum? in ths surface

an irregularity in the surface of a paint film resulting

from the inability of thE ,.let film to "level out" after

king aplied

sprayed paint which miss25 the area being painted an3 falls

upon the surroundin3 surface

c.

32. Flash time:

a.

b. thz dovmvarci flov of 3 rjaint film

c.

d.

the dqree of which a surfxz reflects 1icj-k

the tims ktween ?aint ap?lication and ba!cixj

ths time it takes paint to be dry to the touch

23. Wst

sa3 and gravity is responsibla.

films ihich are too t5ick or contain too much solvent may

'TRUE - FALSE

- - - 3 . SmkinJ is alloircd in th? p a i n t ar2a as long as no on3 is

painting.

TRUE - FALSE

- 1 2 2 -

30. P r ~ z s z c o n t r o l is r x j u i r 2 3 :

a .

:;.

c. t o k a r s 110s t o make c h a r t s

d .

t o ziv? th2 x i n t e r s sc"thincj t o 30

t o noiii tor tha ; x x z 3 ; ? so consis tzncy c a '3-3 esta%is1;22

t o zra5z p a i n t e r s on t h 2 i r a ' i l i t y t o m i n t trrJlctxr,

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i A ;>hysical a?i?lication tsst to 5s given t o each p a i n t o r .

,This is given by the pain t d q a r t m z n t .

NOTE: This is vorth 20 of thz 50 ?Dints on t h i s t s t .

AP?LICATION TEST

1.

2 .

set up a ;rcssarO Fot u i t h P288

spray 1 s e t of Q . p n e l s t r y i n g t o achieve a dry f i l m t h i ckness

of 1.0 m i l s .

3 . c!ice:c :Jzt f i l m

4. check dry f i l m

3 . check sh3en

6. checli h a r 5 m s s

7 . f l u s h pln and ?Ot

- 124 -

MORTON !‘d4ETAbCRAFT CO.

fer Cztification Certificate The named individual is certif ied in accordance with MMC-Paint ing Processes. Qualification and certification complies with M M C st an da rds .

given o n this __ ___. day of ------, __ - ___ -

PLANT MANAGER- P f 3 E S I DENT

1

In N rl

I

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QUALITY IMPROVEMENT PRERAM.

This is an on-going program where ope ra to r s a r s asked to f u r n i s h

input toward so lv ing problems. A Q u a l i t y Crusade Team, made up of

hourly personnel from a l l a r eas of manufacturing, meet and d iscuss

>roblems, and then pursu: co r rec t ive a c t i o n . Thp Plan t Manager is

responsible f o r this program.

- 126 -

Anthony "Tony" Lynn is Finishins General Foreman for Norton Metalcraft, Morton, Illinois. 'Ir. Lynn has been with Morton for 20 years, having held numerous supervisory positions in manufacturing, assembly, and finishing. A s&x-year member of CCA, Mr. Lynn is currently Vice-president of.the Central Illinois Chapter, and past winner of the "User of the Year" award from that chapter.

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