A

Project Stage-I Report

On

“Zero Defect Strategy at System

Level for Multistage Manufacturing in
Paint Shop”
By
Mr. Chikane Dipak S. (Exam Seat no. )
Mr. Deolalikar Amar D. (Exam Seat no. )
Mr. Gandhale Mahendrakumar R. (Exam Seat no. )

Under the Guidance of

Dr. S. C. Bali
From Company: Mr. Girish Poipkar (Accutech Engg. Pvt. Ltd)

Department of Mechanical Engineering,

Vidya Pratishthan’s Kamalnayan
Bajaj Institute of Engineering,
Baramati.
2018-2019
 Vidya Pratishthan’s Kamalnayan Bajaj Institute of
Engineering and Technology, Baramati
Department of Mechanical Engineering

CERTIFICATE

This is to certify that Mr. Chikane Dipak Shankar, Mr. Deolalikar Amar
Devendra, Mr. Gandhale Mahendrakumar Rajendra have successfully
completed the Project Stage-I entitled “Zero Defect Strategy at System Level
for Multistage Manufacturing in Paint Shop” under our supervision, in the
partial fulfilment of Bachelor of Mechanical Engineering of S.P.P. University,
Pune.

Date:

Place:

Dr. S. C. Bali Head of Department

Guide Mechanical Engineering,
VPKBIET, Baramati.

External Examiner Principal VPKBIET,

Baramati

Seal
 ACKNOWLEDGEMENT

The study of “Zero defect strategy at system level for multistage manufacturing in paint
shop” was a source of immense knowledge to me. I would like to express my sincere
gratitude to my guide Dr. S. C. Bali for his guidance and valuable support throughout this
study.
I wish to express my sincere thanks to all staff members of my college for the knowledge
imparted during this course. I would like to thank Head of Department Dr. P. R. Chitragar
and our Honourable Principal Dr. R. S. Bichkar for their cooperation availing required
facility.
Last but not least, I would like to thank all of my friends and family members for their
support and co-operation.

Mr. Chikane Dipak S.

Mr. Deolalikar Amar D.
Mr.Gandhale Mahendrakumar R.

I
 ABSTRACT
Painting process is an important process in automotive industry. The purposes of the process
are to give more attractive appearance to the body or part and to provide the layer of
protection against corrosion and weathering. The painting process are including a few other
processes, which are Pre-Treatment and Electrodeposition (ED) Process, primer process and
Autophoretic coating process. The objective of the project is to identify the problems occur in
autophoretic coating process and reduce the problems to improve the autophoretic coating
process.The methods used to identify the problems are based on the four M method, which
are Manpower, Machine, Method, and Materials. The study implements total quality
management tools to analysis the problems.

Keywords: Autophoretic coating, Corrosion, quality tools, Zero defect,

II
 LIST OF FIGURES
Fig. No. Title Page
No.
1 Air pressure plate 2
2 Back plate 2
3 Brake Chamber 3
4 Spring Brake Chamber 3
5 The cause of air entrapment 8
6 Bubbles Formed in Coatings 9
7 Blistering in rice cooker after use 9
8 Micrograph of solvent pop 10
9 Mud Cracking 11
10 Crater Formation 11
11 Photograph of wrinkled coating surface 12
12 Color mismatch 12
13 Paint adhesion loss 13
14 Histogram for variables 16
15 Pareto chart 16
16 Fishbone diagram 17
17 Scatter diagram 18
18 Flow chart of review process 18
19 Control chart 19
20 Pareto analysis of data observed 22

III
 LIST OF TABLES

Table No. Title Page

No.

1 Check Sheet 15
2 Data record 20

IV
 LIST OF ABBREVIATIONS

ABBREVATION MEANING
4M Manpower, Machine, Method, Material.
APP Air pressure plate
NPP Non pressure plate

INDEX
ACKNOWLEDGEMENT I

ABSTRACT II
LIST OF FIGURES III

LIST OF TABLES IV

LIST OF ABBREVIATIONS V

1. INTRODUCTION 1
1.1 GENERAL 1
1.2 COMPANY 1
1.3 PRODUCT 2
1 Air Pressure Plate
2
2 Back Plate
2
3 Brake Chamber
2
4 Spring Brake Chamber
3
1.4 OBJECTIVE OF THE PROJECT 3
2. LITERATURE REVIEW 4
1.1 COATING 4
1.1.1 Benefits of Coating 4
1.1.2 Coating Processes 5
1. Vapor deposition 5
2. Conversion coating 5
3. Spraying 6
4. Thermal Barrier Coating 6
5. Hot Melt Coating 6
1.2 AUTOPHORETIC COATING 6
1.2.1 Benefits of A-Coat 7
1.3 COATING DEFECTS 7
1.3.1 Air Entrapment 7
1.3.2 Foam 8
1.3.3 Blisters 9
1.3.4 Pinhole / Popping 10
1.3.5 Mud Cracking 10
 VI

1.3.6 Cratering 11
1.3.7 Wrinkling 12
1.3.8 Colour Mismatch 12
1.3.9 Paint Adhesion Loses 12
1.4 DEFECTS PREVENTION 13
1.4.1 Air Entrapment 13
1.4.2 Foam 13
1.4.3 Blisters 13
1.4.4 Pinhole / Popping 13
1.4.5 Mud Cracking 13
1.4.6 Cratering 14
1.4.7 Wrinkling 14
1.4.8 Colour Mismatch 14
1.4.9 Paint Adhesion Loses 14
1.5 QUALITY TOOLS 14
1.5.1 Check Sheets 15
1.5.2 Histogram 15
1.5.3 Pareto Analysis 16
1.5.4 Fishbone Diagram 17
1.5.5 Scatter Diagram 17
1.5.6 Flowchart 18
1.5.7 Control chart 18
3. RECORD DATA 20
4. SUMMARY 22
5. FUTURE PLANS 23
6. REFERENCES 24
VII