PAINT KING SOLUTION PVT. LTD.

PROCESS FLOW DIAGRAM

Item :- FAN BLADE Process Flow Number :- PK / PFC /VGAURD / 01

Process Identification :- Painting

Part No. :- N/A Prepared by :- VIJAY GUPTA

Process Res. :- NIKESH
Model :- N/A Date (Original):- 03-04-2024

Core Team :- Nikesh Yadav,Amrit,Vijay Key Date :- 03 / 07/ 2024 Date (Revised) :-

Process Flow Diagram

Operation
Brief Description of Operation Product Characteristics Process Characteristics
Number

1) Material in the Specified Boxes

Receipt of RM material, Packing having identification for Item Code
10 ----------
material & bought out items. and Item Name
2) Paint materials test certificates.

20 Mounting & Inspection Mounting should be correct Operator / Inspection Skill

Free from Dust, Oil & Spray,Poor

30 Primer Application Thickness
Operator Skill

40 Front Base Coat All dust free product Air pressure 2 to 3 bar

50 Water Transfer As per Reference sample fully Dip the component for 5 to 6min.

60 Back Base Coating As per Reference sample Air pressure 2 to 3 bar

70 Paint Baking Base coat should get dry as per standard

80 Anti Dust Lacqure As per Approved sample Operator Skill

Aesthetic as per component check

90 Inspection of Product sheet
-------

Prodocut free from damages /

100 Packaging scratches
As per Packing Specification

1) Correct Quantity
110 Shipment of Customer 2) Correct lebel Operators knowledge
3) No transit damage

Operation Inspection Storage Shipment

Page 1 of 5
 ( PROCESS FMEA )
Item : BLDC FAN BLADE FMEA Number : PK/FMEA/VGAURD/01
Process Resposibility : Painting Prepared by : VIJAY GUPTA
Key Date : 03-04-2024 FMEA Date(Orig) : 03-04-2024
Model Number :N/A FMEA (Rev) : N/A
Core Team : NIKESH YADAV, AMRIT, VIJAY GUPTA CUSTOMER NAME: V GUARD
C
O D
Process Fuction Action Results
c e
S l Current process controls Resposibility
Potential
a R P & target R
Potential failure mode effect(s) of Potential Cause(s) / mechanisim(s) of failure c t Recommended action(s) Actions
e N completion S O D P
failure u e taken
v s Prevention Detection date N
Requirement
r c
10A). Receipt of RM Parts / Paint Wrong Receipt Production s No verification at the receipt stage Physical verification of Raw material prior to & Identification of material ------- ------- -------

Delay / Stop un-loading for the correct material. on the bag etc.

Requirement :- Damage Material Production Material in inferior packaging. Packing Specification Chart D/RSD/LST/02 Inspection while ------- ------- -------

To receive the Material as Delay / Stop unloading.

per Challan

10B). Storage & Damage / Production Storage method not followed. a) Trained staff & Operator Periodic verification. ------- ------- -------

Inspection of raw / Paint deterioration Delay / Stop b) Storage as per location chart & layout

Material / Cubic Film Material not Production Material location chart not followed a) Material layout plans on the storage rack. Monitoring by the trained ------- ------- -------

Requirement :- traceable. delay b) Identification on each rack / each lot. staff.

To store the material to

prevent the deterioration

10C). Inspection of Not as per the Rejection / No test report and inspections / control at the Supplier a) P.I.D.R., Test certificate with the consignment. Inspection as per the ------- ------- -------
end
(a) RM Parts (b) Paint Material Quality Plan / raw material
Production affect b) Evaluation / revaluation of supplier Quality Plan
(c) Packing material specification

Requirement :-

To check the suitability,acceptability

20. Put material in tray or net

a. Dust Reject / Rework Handling of parts not as per prod.& quality standard 4 a. Mounting as per quality standard. Visual Inspection. ….. …… …..

Requirement :-
b. Article fall down ….."….. ……"…… b. Trained operator. Visual ….. ….. …..
For Better material handling

C. scratches ….."….. …."…. c.Provide Tray Or Net TPM Checklist ….. ……. ……

30.Primer Application a. Dust, Oil, spay on parts. Reject / Rework Primer application is not as per quality standard a.Primer application is not as per quality standard Visual inspection. ….. ……. ……

Requirement :- b. Poor thickness

….."….. b. Trained Operator ….. …… ……. ….
Primer application as per quality standard adhesion.

….."….. ….."….. Visual …… ……. ….

40. Front Base Coat a. By TPM checklist.

a.Dust & non uniform surface Reject / Rework a.Equipment failure. a. By TPM Activity. …… …… …..

Requirement :- b. Shade Variation Reject b.Operator not following standard operating procedure. b.Static charge & dust removal as per prod.standard b. Visual Inspection. …… …….. …..
 C
O D
Process Fuction Action Results
c e
S l Current process controls Resposibility
Potential
a R P & target R
Potential failure mode effect(s) of Potential Cause(s) / mechanisim(s) of failure c t Recommended action(s) Actions
e N completion S O D P
failure u e taken
v s Prevention Detection date N
Requirement
r c
s
Parts should be free from dust & scratches c.Untrained operator. c.Skilled operators. c. Visual ……. …… …..

50.water transfer Improper Film Rework / Reject Non-Optimum Flow of activator Skilled Operator Visual …….. …… …..

Preparation should be as per specification. Shade Variation Reject Untrained Operator As per process standard specification Visual …….. …… …..

60. Base coat application. Low DFT .Mixing ratio not as per standard. As per process standard specification a.Painting Process monitoring records. …….. …… …..
Unsatisfactory
appearance
Requirement :- High DFT Viscosity not as per specification As per process standard specification b. DFT measurement …….. …….. …..

Adhesion & appearance should be as per specification. Shade Variation Reject Viscosity not as per specification As per process standard specification Visual ……… …… …..

a. TPM OF PAINT BOOTH & PAINT BAKING & WATER

a.Environmental dust. a.Set up approval.
DRYING OVENS.

Dust Rework / Rejected b.Contaminated compressed air. b.TPM OF AIR COMPRESSORS. b.Inspection as per Check sheet

c.TPM OF AIR SHOWER

a. Temp.of paint baking not as per As per process standard specification. a. Indication of temperature controller. ….
70. Paint baking Tackiness Rejection ……… …..
standard. b. Speed regulator.
Requirement :-
……… ……… ………
Curing temp. as per prod.std.

80.Anti Dust Dust Reject Environmental Dust Material Handling should be In proper way Visual

Requirement :- Curing Temp. as pe Prord. Stand. Touch up Reject Handling Issues

90. Final Inspection Product Rejection or Production standard & Inspection Inprocess and final inspection as per standard Final inspection report.

Requirement :- nonconfirmities Rework. standard not followed. & reference sample. …… …… ……

Inspection as per Quality plan.

100 & 110. Packing & Transit / handling Rejection or parts Packaging standard not followed. As per packaging standard specification. Visual inspection.

Shipment. damages. may got damage.

…… …… ……
Requirement :-

Packing as per packing std.

 CONTROL PLAN
Prototype : Pre- Launch : ü Production: Key Contact / Phone : Nikesh Date ( Orig.) : 03/07/2024
Date ( Rev.) :
Control Plan Number : PK/CP/VGaurd01
Part Number : Core Team :Nikesh Yadav, Amrit,Vijay Customer Eng. Approval
Date ( if required) : -------
Part Name/ Description : Fan Blade Supplier/ Plant Approval/ ------ Customer Quality Approval /
Date : Date ( if required) : -------
Supplier / Plant : Paintking Unit-3 Vapi Other Approval / Date : ------- Other Approval / Date : ------
( If required.) ( if required )
Characteristics Method
Part / Process Name / Machine,Device Specical Product /Process Evaluation Sample
Process/ Operation Jigs,Tools, For Chara- Specification / Measurement Reaction Plan
No. Product Process Control Method
Number Description. Manufacturing. cteristic Tolerance Technique. Size Freq.
class
Receipt of material - ---- Free from damages Skiled Store person ---- As per Inward inspection Visual 100% ---- Inspection by stores Inform to the
a) Paint Material during the transit. person supplier through
10 A)
b) Packing Material store / purchase incharge

Storage of material at the
designated location.
10B)
Trollesy / Racks Damages / Deterioration Skiled Store person ---- As per Specified location Visual 100% ---- 1. Identification of 1. Inform to store
of the parts. racks / material. incharge
Storage of material 2. Monthly verification of 2. Inform to purchase
at designated location shelf life item Dept. on the
disposition

Inspection of material. Tray or net As per the Quality Inspection Skill ---- As per the Quality plan Incoming Inspection As per ---- Incoming inspection of Inform stores /
(a) Raw material Plan / Paint Material quality plan each lot. Purchase
(b) paint material specification
10C)
(c) packing material ---- ----

Mounting on Tray Tray or net a.putting material as per standard Operator Skill As perprocess std. Visual 100%
Deployment of skilled operator
20 Inspection specification.

primer application Gun Product free from Dust, Operator Skill ---- as per standard work Visual 100% ---- Visual Arrange for training.
30
Spray Deployment of skilled operator

40 front base coat gun Product free from Aire Pressure 2 to ---- As per standard work Visual inspection 100% Continued Visual inspection Recheck & inform to

foreign particles & 3.0bar Procedure process Engr.

smooth surface
50 Water transfer water tank optimum flow of activator as per Specification as per Specification Visual inspection 100% ---- As per process specification / Inform to process engr.

Base coat Spray gun, product free from paint 1) Air pressure 4 Bar 1) As per process Process Monitoring 100% ---- 1) As per Process Specification Inform to process engr.
60 Application equipment run down, dust 2) Skilled Operator specification Standard
2) Skill Matrix
Paint Baking Oven Product free from Oven Temp. 70-80° C ---- As per process Visual inspection 100% Continue Visual inspection & Inform to process engr.
70
Tackiness specification sheet Process Specification sheet
80 anti dust Electrostatic gun Free from dust & Touch up Oven Temp. 140° C at 30 min as per standard Visual inspection 100% Continue Visual inspection Inform to process engr.
Final Inspection Inspection Table Confirm to the Inspection Skill As per check sheet 100% inspection throug 100% Continue Recheck / Reject
100% inspection & QA Audit
90 requirement, reference inspection report cum
sample & Check Sheet audit report
Packaging Packaging Material Damage Free Product ---- As per Component check 100% Inspection 100% ---- Q.A. Audit & Recheck & Repack
As per packing specification
100 sheet packing

Shipment Trolley , vehicle Free from transit damage ---- ---- ---- ---- ---- ---- Vehicle Check list. Inform to Dispatch team
110