WHAT IS PAINT

Paint is the homogenous mixture of Resin, solvent pigments & additivites RESIN: It is the basic solid content in the paint. Resin is need for - Flow -Body appearance -Film formation -Pigment binding -cross linking etc.. SOLVENT: Solvent the volatile material . It mixes with paint to viscosity Settings and other properties.It need for -Reducing viscosity -change speed of dry/flashoff PIGMENTS: Pigments give the shade of the colour to the paint Aluminium flakes for metallic finishes, Mica based.

ADDITIVES: Additives added in paint small quantities to improve certain specific characteristics like UV absorbers- Durability Flow addivites- Leveling Anti settling agents Driers & catalyst. PAINTING Painting basically done to give good apperance, corrosion resistance & prevent From natural Causes like UV, Salt content , Acid content etc.. After painting process the following properties needed to check -Adhesion -Gloss -DOI -Colour -Orange peel - Hardness etc..

WBS PT/ ED

ED OVEN ED BUFFER

SEALER LINE 1 SEALER LINE 2

UBS UBS BOOTH OVEN

PRIMER SANDING

PRIMER BUFFER

PRIMER PRIMER OVEN BOOTH OFF LINE

UBS ED SANDING BUFFER

TOP COAT 1 TOP COAT 1 TOP COAT INITIAL OVEN BUFFER INSPECTION TOP COAT 2 TOP COAT 2 HRS T/C OVEN OK BLACK FINAL POLISHING LINE 1 PBS LINE TAPE POLISHING LINE 2 NOT OK SPOT REPAIR 1

ASSEMBLY
SPOT REPAIR 2

PRETREATMENT:
Pretreatment is the process to remove all contamination from the surface. To make the surface reactive. Pre-treatment mainly done to give corrosion resistance.

Pre treatment Process flow:

ED BATH (DIP) UF-1 (SPRAY) UF-2 (DIP) UF-3 (SPRAY) RCDI-1 (SPRAY) RCDI-3 (SPRAY)

FRESH DI (SPRAY)

HOT WATER RINSE -1(11KL) SPRAY:

To remove the oil contamination and any other foreign materials in the incoming Body from body shop. It improves the degreasing process& reduce degreasing Solution contamination by removing body welding chip, grinding, sanding chips . Control parameters: PH - >10.0 spray pressure- 4-6 kg/cm2 Temperature- 40- 50*c Liquid level from top- 200 mm Spray volume- 4000 l/ min. max

HOT WATER RINSE -2 (11KL)SPRAY:

Control parameters : spray pressure- 1.0- 2.0 kg/cm2 Liquid level from top- 100 mm Spray volume- 1950 l/ min. max pump electric current- 14- 15A

DEGREASING (11KL) SPRAY:

Degreasing process used to improve Phosphate film performance & paint Adhesion power, by removing grease, oil & other foreign particles Control parameters: Alkalinity point- 25- 30 CHEMICAL NAME: oil content- <4000 ppm Gardoclean 4292 circu. Pressure- 1.5 2.0 kg/cm2 Gardoclean 4292B/1 spray volume- 4000l/min.max

DEGREASING ( 106 KL) DIP:

Degreasing done by dipping the car body into the degreasing bath. Control parameters: Free Alkalinity 25- 30 Temperature 50- 54*c Circu.pressure- 1.0-2.5 kg/cm2

WATER RINSE -1 SPRAY (8KL):

This process is done to remove alkali carry over from degreasing process. After degreasing process check for any yellowing or pitting rust on car body Control parameters: Spray pressure- 1.0- 2.0 kg/cm2 Temperature- ambient temp. spray volume-1900 l/min. max

WATER RINSE -2 (75 KL) DIP:

PH- 1-2.0 Circulation pressure- 1- 2 kg/cm2 mist spray volume- 800l/ hr

WATER RINSE- 3 (8KL) SPRAY:

Control parameters: PH - 1.0- 12.5 Spray pressure- 1.0- 2.0 kg/cm2

ACTIVATION :
To activate the body surface so as to obtain uniform fine & dense phosphate crystal Growth during phosphating. Control parameters: Total alkalinity- 1.5 2.5 kg/cm2 PH - >10.0 Spray pressure- 1.5 2.5kg/cm2 Exit spray volume- 1600 l/hr

PHOSPHATING:
To increase corrosion protection, durability of car by providing a solid Formation for adhesion of subsequent coat. It act as a non conducting bond between Paint & metal surface. Control parameters: Total acidity point- 22-25 Free acidity 1.0 - 1.4 zinc content- 1.0- 1.5g/lit coating weight- 1.8 3.0 g/m2 Temperature- 45 50*c

WATER RINSE- 4 SPRAY:

To remove carry over of phosphating solution & to provide durability & uniform Dense of zinc phosphate layer. Total acidity< 1.5 mist spray volume- 1600l/hr spray pressure- 1.0 2.0 kg/cm2 Temperature- ambient spray volume- 1900l/min.max liquid level from top- 12-13 A

WATER RINSE -5 (DIP):

Total acidity < 0.5 circul. Pressure- 1.5- 2.5 kg/cm2 Temperature- ambient mist spray volume- 1600l/hr

DI RINSE 1, 2 (SPRAY) :
To prevent mineral oil contamination into the ED tank & provide uniformly Conductive surface of ED application. Control parameters: circulation pressure- 1.5 2.5 kg/cm2 liquid level from top- 100 150mm mist spray volume- 1600l/hr spray volume- 1900l/hr

DI ENTRY SPRAY:
To improve ED application quality by preventing the body from semi drying& Complete drying. Body should be in full wet condition before entry in to the ED tank. Spray volume- 1000- 1600l/hr

ED TANK DIP (250 KL):

To increase corrosion protection & durability of car by coating through electro Chemical process in order to provide a smooth uniform coating. It has the best ability To coat inner surface. ED process parameters the impact coating appereance, quality & Performance on all substrates. Control parameters for ED : % NVM 18- 23 PH at 25*c 5.5- 5.9 bath temperature- 28-32*c pump pressure- main ciru.- 2-3 bar cooling circulation- 2-3 bar UF module pump- 4-5 bar Rectifier voltage & current inlet bus bar- 0- 170V (max. 2000A) Main bus bar- 180- 270 V (max. 2000A) % solvent 0- 0.8 anolyte flow rate- 100l/hr/cell permeate PH at 25*c- 5- 5.9 permeate solids - 1.5%

UF -1 (ULTRA FILTRATION):
The purpose is to recover carry over paint from carbody, UF rinse will prevent The body from paint dry defects and provide smooth , uniform finish. Control parameters: %NVM - <1.5% Bag filter pressure difference- 1.2 bar.max spray pressure- 0.6- 1.6 bar. spray volume- 956l/min.max

UF-2 (DIP):
Pump pressure- 1.0- 2.5 bar Exit spray volume- 2000- 2400 lph. UF-3 (SPRAY):
% NVM - <0.5% Spray pressure- 0.6- 1.6 bar.

RCD 1 & 2 SPRAY (8KL):

To eliminate paint film defects if any, D.I. water is sprayed. Control parameters: pump pressure- 1.0- 2.5 bar spray pressure- 0.8 1.8 bar spray volume- 1050 l/min. max pressure difference 1.2 bar.

OVEN: EMT of ED OVEN- 165*C / 10 MINS ED DFT- 25 micron

SEALER APPLICATION
Sealer is the process used to avoid water leakages, Rust, noise problems. Sealer applied in the gap between overlapping area in body. Sealer is made of PVC. 1. WHITE SEALER Terolan 5955 HV(Henkel) 2. OIL SEALER- Terolan 5955 LV(Henkel) There is 2 sealer line for sealer application. Line 1 UPH- 28 Line 2 UPH 29

PROCESS FLOW:
Plug fixing& black sealer removal Tailgate &floor area Lamp house Door finish Door

Anti vibration Pad fixing Fuel door

Engine room

Stay fixing

Roof

Keeper

UBS

PLUG FIXING& BLACK SEALER:

-Floor area drain plugs were fixed in this stage. -The extra Black sealer & contamination from ED were removed.

TAIL GATE & FLOOR AREA :

-All floor areas & tail gate area, were sealer application done. -Floor area & cowl area sealer application done -Fix sealer line T/gate stay -After sealer application brushing to be done in the overlapping area Materials: plastic pad-hera wipping tool, brush, sealer gun O type gun, catch up gun. Check points: *sealer application should be monitered in cowl joint area *ensure pannel gaps are filled with sealer *Brushing should ensure sealer filling in pannel gaps.

DOOR HEMMING & HINGE AREA SEALER:

-Apply white sealer in all door area -Apply White sealer in hemming & Hinge area Check points: *Ensure no sealer Bread problem & no appearance defects *sealer wrinkles formation should be checked while application. HOOD & TAIL GATE: -Apply white sealer hood & tail gate required area Materials: Plastic pad, sealer gun- guide nozzle for T/gate, V nozzle for hood

STAY FIXING:
-Fix hood lower, upper stay L& R, -Fix door spring stay for door L&R -Apply oil sealer at door apretures,door frame,lamp housing, door frame inner pannel area.

DOOR FINISHING:
- Apply oil sealer at door apreture, back panel, door inner panel, tail gate apreture,Roof joints. After sealer application the edges corrected by plastic pad. Check points: *Ensure application of oil sealer in fines areas to avoid water leak, Rust, Noise problem *ensure no sealer holes with application

LAMP HOUSE SEALER APPLICATION:

-Apply oil sealer in side outer comb i lamp housing L&R. - Final Hera work L&R

ENGINE ROOM :
-Apply oil sealer in over lapping areas of F/ apron, s/abs, cowl side, inner panel, roof, Comb i lamp housing upper sealer application L&R. -Hera work to be done.

ANTI VIBRATION PAN FIXING:

Anti-vibration pad is for improving anti vibration and anti-noise of a body.

FUEL HOUSE:
Oil sealer applied in TGS passage, Front wind shield, fuel filler areas and fuel house area

ROOF:
Oil sealer applied in roof area. Check points: *No gap should be available after oil sealer application.

KEEPER:
Check for sealer miss out check for sealer contamination

UBS- UNDER BODY SEALING Sealer application done in the under body area. PROCESS FLOW
Masking Sealer application Robot Manual touch up& Brushing Deadner&RPP Application Robot

Oven

Wipping

Demasking

Deadner&RPP Application Manual

MASKING: To protect the under floor drain holes, bolt, wheel house inner hole, Back panel, under floor etc.. From being contaminated by deadner. So masking done that Areas. Masking tape size varies by 1, 2, 4 depends on area need to mask. Rubber plug Inserting, Aluminium paper cover for bolts, black paper these materials were used to avoid Deadner application & vibration prevention. SEALER APPLICATION ROBOT: Sealer application done by robot in the under body areas to avoid rust, noise Sealer viscosity: White sealer- 950-1350 poise at 20*c Oil sealer- 150- 210 poise at 20*c

Sealer application done by 6 robots in overlapping areas of front Apron, dust cover panel,Cover match bracket, center floor panel, dash panel, and other under body areas. MANUAL TOUCH UP AND BRUSHING: The areas were not covered by Robot that areas manual applied. After touch up Brushing done to even the sealer in the overlapping area

DEADNER & RPP APPLICATION ROBOT: Deadner & RPP is used to improve anti-noise, anti-vibration, anti rust. Deadner Coated in under floor area, spare wheel house areas. Deadner thickness- 800 micron RPP thickness- 500 micron Deadner WFT Checked by special guage. Deadner & RPP applied by the help of Kawasaki made Robots. First 2 Robots apply deadner & other 2 applies both deadner & RPP.
DEADNER APPLICATION & RPP APPLICATION MANUAL: The uncovered area of the body under floor deadner applied manually & side sill area RPP applied. Manual application done by manual gun. Deadner thickness manual- 600 micron RPP thickness manual- 400- 600 micron DEMASKING: The masking papers were removed in deadner application areas.

WIPPING: *Sealer contamination should be completely checked. *Ensure no deadner & RPP in wheel house& sill panel *wipe vertically with solvent OVEN: UBS OVEN EMT- 140*C/ 20 Mins

ED SANDING
ED sanding is to remove all problems of ED stains, sealer contamination, sanding dust, oversprayed sealer, ED defects & other Foreign materials PROCESS FLOW:
Roof area sanding T/ gate ( interior& exterior) & QTR panel Hood(inte & exter)& Fender L&R Rear Door (inter & exter)

Keeper stage

L&R Front Door (inter & exter)

ED Sanding done in the above process flow. Roof area, tail gate interior , exterior, L&R Rear Door interior , exterior and L&R Front door interior and exterior areas were ED Sanding done for all ED related concerns. After sanding wipe that area by using tag rag. Vaccum type sanding machine with sand paper disc used to sand heavy dust & C/M

Materials used:
*Tag rag 8 body/ cloth *Vaccum Type sanding machine *Sanding paper 400 *Sanding paper disc roll 320, 400 grade. Defects: Metal contamination Black sealer ED stains Sealer contamination Sanding out dust Over sprayed sealer Permeate ooze out( oil mark) TYPES OF SANDING: Round type sanding Narrow type sanding Fold Back up pad

SURFACER BOOTH
PROCESS FLOW
Surface preparation Surfacer Manual spray Surfacer Robot Application Oven Surfacer sanding

Primer application done in interior by manual & exterior by Robot.

SURFACE PREPARATION: Before surfacer application the car body to be prepare for painting process.
-auto air blow done for whole car body in the entry of preparation

-wipe the surface using tack rag in Roof, Hood, Vertical (exterior, door apreture), Pillar & qtr panel, Trunklid areas. Check points: *All surface area should be wipped out *Do tag rag wipping after sanding *10% over lap wipping SURFACER MANUAL SPRAY: Depends on the display shows the colour the manual spray done for interior areas, of Tail gate inner apreture, side structure L&R, Hood, Engine room , Back panel. Manual touchup done for ED sanded Area.

Apply wash primer in the exposed Bare metal area.

SURFACER MANUAL SPRAY: Depends on the display shows the colour the manual spray done for interior areas, of Tail gate inner apreture, side structure L&R, Hood, Engine room , Back panel. Manual touchup done for ED sanded Area. Check points: -Ensure there is no poor hiding &Rundown after application
-Distance between gun & surface should be 30 cms -Humidity in booth 65-75% -Air velocity 0.4m/s , Spray air pressure- 4.5 bar -Gun speed & spray distance to be kept constant -Over lap of spray should be 50% -Maintain spray Angle-90*

SURFACER ROBOT APPLICATION:

The exterior areas of the car body Primer application done by 7 axis Robot . All vertical & Horizontal areas were painted by 6 robots.

LH Side- R11 , R12 , R13 RH Side- R21 , R22 , R23 Robot make DURR ROBOT PARAMETERS:
H.V. - 60-80 KV Turbine speed- 30000 45000 RPM Flow rate 70- 600 CC/Min Shaping Air 50 -300 NL ,Spray distance- 26- 30cm

ROBOT SIGNAL TRANSFER: Body detect sensor Ultrasonic sensor MIS (Manual Input station)

PLC
Robot controller OVEN: EMT 160* For 20 Mins. Fresh air zone temperature- 120*c Heat up zone 1- 160*c Heat up zone 2 180*c Heat up zone 3 180*c Heat up zone 4 180*c Oven Holding temperature 1 190*c Oven Holding temperature 2 160*c Robot

SURFACER (PRIMER) SANDING

PROCESS FLOW
C&B Class sanding Roof Sanding Hood & Engine room Tail gate (interior& Exterior) Door A class, Fender & Qtr panel

Keeper

Door interior

After primer application the car body surface checked for any ED Stains, Sealer contamination, Paint defects, Sanding dust etc..The defects were find out and sanded by manually with 600, 800 grade sanding paper. For heavy problems sanding done by vaccum type sanding Machine. After sanding wipe the sanded area with Tag rag.Fixing Masking tape in heavy rework area for indentification to do touch up in t/ coat booth. MATERIALS: Tag Rag Vaccum Type sanding Machine Sanding Paper 600, 800 grade Nylon gloves Masking tape

TOP COAT BOOTH 1

PROCESS FLOW
Top coat preparation Top coat Base Manual spray Top coat base Robot spray Demasking Clear Manual spray

Oven

Flash off zone

Clear coat ASM

PROCESS FLOW
Top coat preparation

TOP COAT BOOTH 2

Top coat Base Manual spray Top coat base Robot spray Clear Manual spray

Oven

Flash off zone

Demasking

Clear coat Robot Spray

TOP COAT PREPARATION: Before Top coat base application the car body to be prepare for painting process. -auto air blow done for whole car body in the entry of preparation -wipe the surface using tack rag in Roof, Hood, Vertical (exterior, door apreture), Pillar & qtr panel, Trunklid areas. Check points: *All surface area should be wipped out *Do tag rag wipping after sanding *10% over lap wipping * Check no should be loose or vibrate * Ensure that the sides of Tag rag are changed for every body TOP COAT BASE MANUAL SPRAY: Depends on the display shows the colour the manual spray done for interior areas, of Tail gate inner apreture, side structure L&R, Hood, Engine room , Back panel. Manual touchup done for Primer sanded Area.

Check points: -Ensure there is no poor hiding &Rundown after application

-Distance between gun & surface should be 30 cms -Humidity in booth 65-75% -Air velocity 0.4m/s -Gun speed & spray distance to be kept constant -Over lap of spray should be 50% -Maintain spray Angle-90* -Application Air Pressure should be only 4.5 Bar

TOP COAT BASE ROBOT APPLICATION:

The exterior areas of the car body Primer application done by 7 axis Robot . All vertical & Horizontal areas were painted by robots. Metalic , solid, Mica shade base paint application done.

Robot make DURR Cleaning of Bells:

* Clean the Bell cup with wipping rag during tea, lunch, & dinner time on daily basis. *Dip the bell in the solvent at the end of production. *B ell cup to be clean once in day.

ROBOT PARAMETERS:
H.V. - 40-80 KV Turbine speed- 35000 55000 RPM Flow rate 70- 440CC/Min Shaping Air 120 -300 NL ,Spray distance- 26- 30cm

CLEAR MANUAL SPRAY: Clear spray done by manually in car body interior areas. Front door apreture area Rear door apreture areas, Frame, B pillar & door inner area were clear sprayed. Ensure Doors were closed properly after completion of work.

Check points: -Ensure there is no poor hiding &Rundown after application

-Distance between gun & surface should be 30 cms -Humidity in booth 65-75% -Air velocity 0.4m/s , Spray air pressure- 4.5 bar -Gun speed & spray distance to be kept constant -Over lap of spray should be 50% -Maintain spray Angle-90* CLEAR ROBOT SPRAY: ( LINE -2 ) After clear coat manual spray the body exterior areas clear application done by 4 robots.(DURR) All vertical and horizontal areas of body were clear sprayed by Robots. CLEAR ROBOT SPRAY: ( LINE -1) After clear coat manual spray the body exterior areas clear application done by Automatic Spray Machine..(SAMES) All vertical and horizontal areas of body were clear sprayed by ASM.

ASM PARAMETERS:
H.V. -- 50- 75kv Flow rate- 60 240 cc/min Shaping Air 20 32 db Turbine Speed 27000 35000 RPM

DEMASKING:
What are all the areas we need not to paint that areas were masked. Those Masking removed in this stage for different models.

OVEN:
The wet film getting dried inside the oven area
Top coat oven process time 40 mins Oven Fresh air Temperature 120*c Oven Heat up Zone 1 180*c Oven Heat up Zone 2 175*c Oven Holding zone 175*c

Here only the primer, base coat , clear coat paint were prepared with required Composition of solvent, addititives to give the required property. In PMR the paint viscosity , temperature maintained by separate system.Paint transfered to paint mixing tank to application area by Proper paint supply &Circulation system.
LINE VOLUME:
Primer - 200 liters Base - 300 liters Clear - 300 liters

PAINT MIXING ROOM

CONSUMPTION / CAR:
Primer Base Clear - 1.5 liters/car -2.5 liters/ car -1.5 liters/ car

FORD CUP: Ford cup used to measure the viscosity of the paint. F3 Ford cup Base coat( 3mm dia) F4 Ford cup Clear coat(4 mm dia) SUPPLIERS: 1. Asian PPG 2. KCC

PROCESS FLOW
Initial inspection

FINAL LINE
Polishing Interior sanding& Polishing

Wet sanding

Keeper

Both stay removal

Overslam Bumper installation

Keeper

Touch up

Initial inspection done for all painted bodies, in the above process sequence. For each car body painted car inspection card provided for easy indentification of defects, and location.
Wet sanding: Wet sanding done for Hood area L&R , Tail gate L&R, and other interior and exterior areas. Check for visible defects like Dust, blister, contamination etc.. After wet sanding wipe the sanded area using Dry Hosiey cloth. Polishing done for sanded area using Polishing paste Glaze. Material: Sand paper 2000 grade, Paste glaze, Polishing machine, Buffing pad 3 Machine RPM- 3200 rpm(DYNABRAD) , Paste- 3M

SPOT REPAIR
Major paint problems car bodies were go to spot Repair and repair done and made Ok.

Check points:
use masking tap on edges to avoid over spray Average length of the t/p should range from 11.5 cm Ensure proper merging of Thinner Use half faced mask Blow Hot air at distance range from 15- 20cm to avoid air bubble problem

Duration & Temperature of Hot air Blow:

TOUCH UP DRY ONLY B/C TIME 3 Mins 1 Min TEMPER . 50- 60*c 35 40*c B/C + T/C

SHADE COLOUR

SOLID METALLIC

WHITE SLEEK SILVER

TIME TEMPER. 5 mins 55- 63*c 2 min 40- 49*c

BLACK TAPE FIXING & HRS

BLACK TAPE FIXING:
Black tape fixing for appearance for required models only. After Black tape Fixing car body moves to PBS.

HRS (Heavy repair sanding):

Heavy repair sanding to be done in HRS stage, after sanding the full body is Wipped out and send to do top coat booth again.

ASSEMBLY SHOP
PROCESS FLOW
PBS TRIM 1 TRIM -2 CHASIS 1

Assembly shop 1 UPH- 45 Assembly shop 2 UPH - 6 CHASIS 2 FINAL LINE 1,2,3 OK LINE

TOUCH UP

SHOWER

ROAD TEST

ROLL& BRAKE

PDI In assembly shop various parts were assembled and each line keeper stage defection record System followed. Paint shop related defects were corrected by paint shop persons. If any interior, Exterior T/ up needed means inside assembly line booth t/p done. After touch IR lamp heating , Hot air blow heating done. We find out the painting related Problems written in the vehicle Inspection card provided by assembly.

PDI (PRE DELIVERY INSPECTION)

PDI Defect out flow is 1.6% PDI also fully vehicle quality checked. PDI Vehicle inspection sheet provided for each vehicle. That sheet paint shop related concerns were written and that vehicle moved to touch area And correction done.

GQMS CODE:
P AQL Q BELOW 2 MINS M- 2 -20 MINS REPAIR H HEAVY REPAIR MORE 20 -30 MINS Y DENIAL S SERIOUS PROBLEMS Z IMPOSSIBLE TO REPAIR NEED IMPROVEMENT.

Check points for touch up area:

-Defects repaired or not -If any loose parts -Check polishing compound overspray -Dust in paint -If any contamination -Verify the check sheet before sign off -Check the paint guns.

MAJOR DEFECTS:
Fitment problems (excess sealer) T/up( sag, dust, mottling, Batch mark, Less paint, Sealer contamination etc Shower leak ( sealer hole in Roof , Tail gate, cowl ) Scratch grade: HAIR LINE Affects slightly in clear coat only SUPERFICIAL 50% affect on clear coat only NORMAL Affects on clear & Base coat only DEEP Affects on Clear, Base, Primer coat only