DEFECTS RE - ACTION PLAN OF PAINT SHOP kamal

Stage Problem Cause Remedies

Adhesion test Fail Low free alkalinity Bring free Alkanity in range (18 to 22 point) by adding 4357A and 4357 B (for increase by
1 point
Temp addShould
of bath 4357A - 2.3
bring kg and
in spec.( 55 4357
deg to B
65-deg
1.8C).
kgCheck air supply in air operating valve of hot water line
Low Bath Temp supply.check temp setting at temperature meter.
Less Phosphate coating Nozzles Chouk Clean nozzles.
High oil content Run Oil Separation unit contineously.
KOD High oil content Run Oil Separation unit contineously.
White Patch Mark Temp of bath Should bring in spec.( 55 deg to 65 deg C). Check air supply in air operating valve of hot water line
High Bath Temperature
supply.check temp setting at temperature meter.

Water Breakage High Bath Temperature Temp of bath Should bring in spec.( 55 deg to 65 deg C). Check air supply in air operating valve of hot water line
supply.check temp setting at temperature meter.
Less Surfactant in bath solution Add Nipaklin 4357 B - 15 kg in tank

Adhesion test Fail or Less

Phosphate coating
Low freee alkalinity Bring free Alkanity in range (18 to 22 point) by adding 4357A and 4357 B (for increase by
1 point add 4357A - 8.5 kg and 4357 B - 6.5 kg

DEGREASE
White Patch Mark
Water Breakage
White Patchy Appearance or
WATER RINSE I & II
Paint Roughness
Non uniform phosphate
Surface Activation coating or phosphate crystal
structure is uneven
Low Bath Temp
Circulation pressure is low
High oil content
High oil content
High Bath Temperature
High Bath Temperature
Less Surfactant in bath solution
High Total Alkanity of Bath
Circulation or spray pressure is low
NO water Cascading
Nozzles Chauk
Total Acid of bath is low
pH of bath is low
Bath Circulation pressure is low
Temp of bath Should bring in spec.( 55 deg to 65 deg C). Check air supply in air operating valve of hot water line
supply.check temp setting at temperature meter.
Circulation pressure Should bring in spec.(0.8 to 1.5 kg/cm2)
Run Oil Separation unit contineously.
Run Oil Separation unit contineously.
Temp of bath Should bring in spec.( 55 deg to 65 deg C). Check air supply in air operating valve of hot water line
supply.check temp setting at temperature meter.
Temp of bath Should bring in spec.( 55 deg to 65 deg C). Check air supply in air operating valve of hot water line
supply.check temp setting at temperature meter.
Add Nipaklin 4357 B - 30 kg in tank
Start Water Cascading or add fresh soft water
Clean nozzles
Circulation pressure Should bring in spec. by adjusting Delivery valve
Maintain
Drain Tank Total
,Clean Acid
& makeofRefresh
bath in spec, ( 7 to 15 point ) by adding GN ZS ( for increase by 1
point add GN ZS 1 kg)
Circulation pressure Should bring in spec.( 0.8 to 1.5 kg/cm2 ) by adjusting delivery valve

Phosphate coating uneven or

crystal structure uneven
Total Acid of Bath is out of specification Total acid of bath should bring in specification ( 18 to 22 point )by adding Nipaphos 3020
AR 2 (for increase by 1 point add Nipaphos 3020 AR2 - 12 kg)

Yellowish coating Free Acid of bath is high Maintain Free Acid in given space.(0.7 to1.1) by adding Neutriliser 4055 (for decrease by
0.1 point add Neutriliser 4055 - 700 gm)

Phosphate Blue coating,thin caoting Acclerator of bath is high Maintain acc in spec. (2.0 to 3.5) by adding Nipaphos 4707 (for increase by 1 point add
Nipaphos 4707 - 1 kg)

Low total acid Total acid of bath should bring in specification ( 18 to 22 point )by adding Nipaphos 3020
less coating wt. AR 2 (for increase by 1 point add Nipaphos 3020 AR2 - 12 kg)

Low Accelerator
No soft water cascading
Bath contaminate
Sludge on processed part or
Watar Rinse III & IV Total Acid is out of spec
Paint Dust
tank nozzle not working
Circulation pressure is low
Maintain acc in spec. (2.0 to 3.5) by adding Nipaphos 4707 (for increase by 1 point add
Nipaphos 4707 - 1 kg)
Start soft water cascading or overflow in tank
Clean tank and make refresh
Clean nozzle
Circulation pressure Should bring in spec.by operating valve

Pinholes on painted part or High Conductivity of bath water (more than 20 Maintan conductivity & ph of water within spect limit.by adding DM Water
DM RINSE I
Paint Blister micron)
start overflow low conductivity DM water in bath at rate 5 LPM

Low NV %
set NV% in space.( 12 -16 %) by adding F1 and F 2 (for increase by 1% add F1 -65kg and
F2 - 227 kg in bath)
Low film thickness less voltage supply Incrase voltage from DC Rectifire

pH is low Manitain ph in specification (5.6- 6.2) by adding Additive EDD in bath (for increase by 0.1
add Additive EDD - 3 to 4 kg )
voltage supply is high decrease voltage from DC Rectifire
DFT High / Orange Peel Manitain ph in specification (5.6- 6.2) by adding Additive M in bath (for decrease by 0.1
Paint pH is high
add Additive M - 2 to 3 kg )
Paint pH is high
Manitain ph in specification (5.6- 6.2) by adding Additive M in bath (for decrease by 0.1
add Additive M - 2 to 3 kg )
paint Cogulation Manitain Temperature in specification (28 to 30 Deg C) check chiller unit compressor performance, it should not
CED BATH Bath Temp is High triped and Check air supply in air operating three way valve of chilled water line, Check PHE input and out put
pressure and temperature ,chec

low pH of ED bath Manitain ph in specification (5.6- 6.2) by adding Additive EDD in bath (for increase by 0.1
add Additive EDD - 3 to 4 kg )

conductivity of anolyte tank is high Manitain Conductivity in specification (500-1000 microS) by adding DM water and also
Pin hole and paint wash
check colour of anolyte solution . If colour of solution is blackish than check anodes inlet
and outlet one by one and then find faulty anode and water connection of that

conductivity of bath high Manitain Conductivity in specification (1000-1600 microS) by adding DM water ( for
decrease 50 microS conductivity of bath add aproxi. 50 ltr of DM water.)
bath contaminate start permmeate cascading
UF1 UF2 & DM ED drops
NV%age of bath is more than 1% Tank clean and make refresh if bath contaminate
Less gloss Oven temp is high Adjust setting of Oven Temp. within spec (190 to 210 deg C ) from display
Bend test fail Avoid to hold parts in oven more than 42 minute.
Impect tesh fail
BAKE OVEN
High gloss Oven temp is low Adjust setting of Oven Temp. within spec (190 to 210 deg C ) from display
MIBK (Solvent) fail
paint dust Due to oven dust clean oven