PAINT SHOP

PROJECT
How 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 & Manufacturing
Shahbaz Baig - NED - Industrial & Manufacturing
 Usage of Lacquer and Thinner
(Fuel Tank)

1st coat, 207 Other, 93 3rd coat,

2nd coat, 31
62

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)
Repainted,
35

Painted
Once, 555

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 Contamination
1. 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 Measures
 Put 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 Solution
 Upon 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 Solution
 Then 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 Solution
 Soft Wall Clean rooms
 Cleanroom
 A 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. Temperature
2. Humidity
3. 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 Solution
 As 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 Solution
 Humidifier and Dehumidifier
 Proposed Solution
 Air shower pass through doors
 Air Shower
 Clean 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