Sample testing report

Sample Testing Report Inspection Perameters

Oven Pre-Treatment Scratch Impact
Srl No. Sample Thickness Ral Code Velocity Dft Gloss
Temperature Nail Test Test Test
1 2 MM (OUTER SIDE ) RAL9001 180 46 VFD OK 93 TO 98 OK - 92.2
2 2 MM (INNER SIDE) RAL9001 180 46 VFD OK 118 TO 149 OK - 89
3 2 MM (INNER SIDE) RAL5012 180 46 VFD OK 76.5 TO 94 OK - 69
4 2 MM (OUTER SIDE) RAL5012 180 46 VFD OK 70 TO 98 OK - 91
5 2 MM (INNER SIDE) RAL2002 180 46 VFD OK 106 TO 119 OK - 69
6 2 MM (OUTER SIDE) RAL2002 180 46 VFD OK 82 TO 89 OK - 90
7 5 MM (INNER SIDE ) RAL9001 180 46 VFD OK 76 TO 100 OK - 72
8 5 MM (OUTER SIDE) RAL9001 180 46 VFD OK 66 TO 200 OK - 67
9 5 MM (INNER SIDE) RAL5012 180 46 VFD OK 95 TO 105 FAILED - 89
10 5 MM (OUTER SIDE) RAL5012 180 46 VFD OK 85 TO 93 FAILED - 96
11 5 MM (INNER SIDE) RAL2002 180 46 VFD OK 72.8 TO 86 OK - 84
12 5 MM (OUTER SIDE) RAL2002 180 46 VFD OK 68 TO 75 OK - 90
AS THE 5MM SAMPLE(RAL5012) FAILED AT 46 VFD ,2 TRIALS WERE TAKEN AT 24 VFD SO THAT HEATING TIME IS INCREASED
13 5 MM (INNER SIDE) RAL5012 180 24 VFD OK 95 TO 102 OK - 92
14 5 MM (OUTER SIDE) RAL5012 180 24 VFD OK 67 TO 97 OK - 93
15 5 MM (INNER SIDE) RAL5012 180 24 VFD OK 75 TO 90 OK - 65
16 5 MM (OUTER SIDE) RAL5012 180 24 VFD OK 71 TO 89 OK - 67.7
ALSO A 5MM SAMPLE (RAL2002) WAS TESTED AT 46 VFD MAINTAINING DFT HIGH
16 5 MM RAL2002 180 46 VFD OK 130 TO 150 FAILED - 67.7

POWDER PEELOFF WAS VISIBLE AT EDGES ALONG THICKNESS FOR BOTH 2MM AND 5MM SAMPLE FOR ALL POWDERS WHEN STRUCK WITH SHARP EDGE

THE OVEN TEMPERATURE FOR ALL POWDERS MAINTAINED IS 180 DEGREE CELSIUS WHICH DOESN'T MEET WITH BAKING SCHEDULE MENTIONED ON BOXES OF POWDER.
ALSO NO TTR TEST CARRIED OUT FOR VALIDATING IF THE OVEN TEMPERATURE IS MAINTAINED
THE GLOSS AND DFT READING OF SOME SAMPLE INSPECTED WAS ON HIGHER SIDE.
SHADE PHYSICALLY VERIFIED AT 24VFD AND 46 VFD ARE SIMILAR BUT DIDN'T MATCH SHADE CARD (RAL5012)
THE CONVEYER SPEEDS MANUALLY CALCULATED WERE FOUND AS 2.06 M/MIN FOR 46 VFD AND 1.05 M/MIN AT 24 VFD.(DIDN'T MATCH WITH THE DATA ON
DOCUMENT DISPLAYED AT POWDER COATING AREA )
MANUALLY TIME TAKEN BY A COMPONENT TO TRAVEL IN OVEN FROM START TO END WAS NOTED AND FOUND AS 13 MIN AT 46 VFD AND 25 MIN 30 SEC AT 24 VFD

BAKING SCHEDULE MENTIONED ON POWDER BOXES

RAL5012 200 DEG FOR 10 MIN
RAL7035 180 DEG FOR 15 MIN
RAL9001 200 DEG FOR 10 MIN
RAL2002

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 ROOT CAUSE ANALYSIS

MATERIAL MAN MACHINE

RIGHT GRADE OF MATERIAL USED
WHICH IS SUITABLE FOR
POWDERCOATING
TRAINED AND SKILLED OPERATOR
AT POWDER COATING
THE PRETREATMENT
PROCESS,POWDERCOATING BOOTH ,
OVEN AND CONVEYER TOLS AND
GAUGES ARE CALIBRATED AND
VERIFIED

POWDER COATING PEEL

OFF
.

MEASUREMENT METHOD ENVIRONMENT

THE DIFFERENT PARAMETERS (like 1 PROPER PRETREATMENT N.A.
oven temperature , conveyer PROCESS
speed) ARE MEASURED AND 2. PROPER PARAMETERS SET FOR
VERIFIED POWDERCOATING AND POWDER
FUSSION PROCESS

ANALYSIS :
1. MATERIAL
As per the B.O.M, HR material is mentioned . But HR has no adhesion property to powder

The material used for punching and further processing of canopy as confirmed by production is HRPO.

2. MAN
Trained and skilled operator present at powdercoating area

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 ROOT CAUSE ANALYSIS

3.MACHINE
The gauges and tools used for powdercoating including DFT meter are callibrated

4. MEASUREMENT
Tritation are performed and the pointage of chemicals are verified
Nail test is performed for verifyong the pretreaatment process.
No test carried out for checking if oven temperture is maintained
For each new sample of powder scratch test, dft, impact test , salt spray test is performed

5.METHOD
BAKING SCHEDULE MENTIONED ON POWDER BOXES
RAL5012 200 DEG FOR 10 MIN
RAL7035 180 DEG FOR 15 MIN
RAL9001 200 DEG FOR 10 MIN
RAL2002
The baking schedule mentioned on powder boxes does not meet with one followed at powdercoating area
The temperature of oven is maintained at 180 degree celsius for all powders
Also the speeds mentioned at given VFD at powdercoating area dont match with the speeds calculated manually at given VFD.

6. ENVIRONMENT
N.A

THE POINTS HIGHLIGHTED IN RED NEED TO BE CONFIRMED FOR THE PROCESS WHICH WE FOLLOW AND AMKE CHANGES IF REQUIRED .NEED THE CONFIRMATION ON
SAME.

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CALCULATIONS AND OTHER OBSERVATIONS

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CALCULATIONS AND OTHER OBSERVATIONS

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 RAL 5012 SCRATCH TEST

2MM RAL5012 AT 46 VFD . SCRATCH TEST PASSED

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 RAL 5012 SCRATCH TEST

5MM RAL5012 AT 46 VFD . SCRATCH TEST FAILED

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 RAL 5012 SCRATCH TEST

5MM RAL5012 AT 24 VFD . SCRATCH TEST PASSED ( SAMPLE 1)

3MM RAL5012 AT 46 VFD . SCRATCH TEST PASSED

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 RAL 5012 SCRATCH TEST

3MM RAL5012 AT 46 VFD . SCRATCH TEST PASSED

6MM RAL5012 AT 46 VFD . SCRATCH TEST FAILED

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 RAL9001 SCRATCH TEST

2MM RAL9001 AT 46 VFD . SCRATCH TEST PASSED

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 RAL9001 SCRATCH TEST

5MM RAL9001 AT 46 VFD . SCRATCH TEST PASSED

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 RAL2002 SCRATCHTEST

2MM RAL2002 AT 46 VFD . SCRATCH TEST PASSED

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 RAL2002 SCRATCHTEST

5MM RAL2002 AT 46 VFD . SCRATCH TEST PASSED

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 RAL2002 SCRATCHTEST

5MM RAL2002 AT 46 VFD . SCRATCH TEST FAILED (DFT HIGH)

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