Acknowledgment

We would like to express our deepest appreciation to all those who provided us the possibility to complete

this report. A special gratitude we give to our instructor of Business Process Analysis (course), Dr. Zahoor

Sarwar, whose contribution in stimulating suggestions and encouragement, helped us to coordinate especially

in writing this report.

Furthermore we would also like to acknowledge with much appreciation the vital role of manufacturing head

of Andrew Paints , Mr. Shamim Ahmed, for who gave the permission to use all required information to

complete the research on “Process Analysis of Paint manufacturing firm producing 2 different qualities

of paint .” and helping us to conduct the actual research. Last but not least, thanks go to my team mate,

who help me to assemble the parts and gave suggestions about the task. We have to appreciate the guidance

given by our Bahria University, Islamabad Campus.

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 Abstract

This report aims to provide details about process analysis of Andrew paints , and their strategies. Process

Analysis is a form of writing designed to explain the reader how a physical work takes place with the series of

steps. A process analysis can be used to improve understanding of how the process operates, and to determine

potential targets for process improvement through removing waste and increasing efficiency. We selected

Andrew paints as a good challenge to work on. It includes processing of raw material into a finishing

good (manufacturing of paint) and measures of quality control.

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 Summary

The paint industry produces a huge variety of products that protect, preserve, and also beautify the objects to

which they are applied. Paint is generally custom-made to fit the needs of customers. Typical products include

architectural coatings (e.g. house paints), industrial coatings (e.g. automotive finishes, wood furniture and

fixture finishes), and special purpose coatings (e.g. traffic paints, roof coatings). Paint is composed of

pigments, solvents, resins, and various additives. The pigments give the paint color, solvents make it easier to

apply, resins help it dry, and additives serve as everything from fillers to ant fungicidal agents. Other Raw

Materials which are being use in manufacturing are Chemicals which are used in the production processes,

and in the quality control laboratories for raw materials and products. Biocides are used in the manufacture of

the wood preservatives paints, and they are also used in the manufacture of water-based paints. Paints are used

for interior and exterior house painting, boats, automobiles, planes, appliances, furniture, and many other

places where protection and appeal are desired. All over the world the paint industries uses the same

manufacturing process which includes.

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Contents
Chapter 1 ........................................................................................................................................ 6
1.2 Project Scope ........................................................................................................................... 6
1.3 Research Purpose .................................................................................................................... 6
1.4 Sources of Information .............................................................................................................. 6
1.5 Oriented Goals.......................................................................................................................... 6
1.5.1 Methodology....................................................................................................................... 7
1.6 Research Procedure ................................................................................................................. 7
1.6.1 Exploratory Research ......................................................................................................... 7
1.6.2 Interview ............................................................................................................................. 7
1.6.3 Interview Schedule ............................................................................................................. 7
Chapter 2: ....................................................................................................................................... 8
2.1 Literature Review ...................................................................................................................... 8
Chapter 3 ...................................................................................................................................... 10
Paint and its Classification ............................................................................................................ 10
3.1 What is paint ? ................................................................................................................... 10
3.2 Main roles of any paint are: ................................................................................................. 10
3.3 Paint’s Classification ............................................................................................................... 11
3.4 Quality policy .......................................................................................................................... 11
3.5 Focusing our customer ........................................................................................................... 11
Chapter 4 ...................................................................................................................................... 12
4.1 PROCESS ANALYSIS: ........................................................................................................... 12
4.2 PRE-PRODUCTION PHASE .................................................................................................. 13
4.2.1 Forecasting ...................................................................................................................... 13
4.2.2 Location............................................................................................................................ 13
4.2.3 Human resource and job design ...................................................................................... 13
4.2.4 Scheduling ....................................................................................................................... 13
4.3 What is in a Can of Paint? ...................................................................................................... 14
4.3.2 Binders: ............................................................................................................................ 15
4.3.3Additives:........................................................................................................................... 15
4.3.4 Solvents: .......................................................................................................................... 15
4.4 Process Flow Diagram of Water Base Paint ........................................................................... 16
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 Fig4.4.1 Process diagram of water base ................................................................................... 16
4.5 Process Flow Diagram of Oil Base Paint ................................................................................ 17
4.5.1 Process Diagram of Oil Base ........................................................................................... 17
4.6 Keeping and storing of different raw material are in:............................................................... 18
4.7 Temperature: .......................................................................................................................... 18
4.8 Issues of Raw Material ........................................................................................................... 18
Fig 4.8.2 Pigment powder storage ............................................................................................ 19
Fig 4.8.3 Solvent and binders opened in heat ........................................................................... 20
4.9 Kaizen Rule for Raw Material: ................................................................................................ 20
Chapter 5 ...................................................................................................................................... 21
5.1 The Manufacturing Process of Paint Industry: ........................................................................ 21
5.1.1 Making the paste .............................................................................................................. 21
5.1.2 Dispersing the pigment..................................................................................................... 21
5.1.3 Thinning the paste ............................................................................................................ 21
5.1.4 Canning the paint ............................................................................................................. 21
5.2 Manufacturing Process of Andrew Paints ............................................................................... 22
5.3 Problems Occurs During Manufacturing Process ................................................................... 22
5.3.1 Kaizen applied:................................................................................................................. 23
5.4 Machines Used In manufacturing the paint: ............................................................................ 23
5.4.1 Attritor .................................................................................................................................. 23
5.4.2 High Shear Mixer ................................................................................................................. 23
5.4.3 Tinting .............................................................................................................................. 24
Fig 5.4.4 Tinting Cans ............................................................................................................... 24
5.4.5 Issue:................................................................................................................................ 24
5.4.6 Kaizen Applied: ................................................................................................................ 24
5.4.7 Canning ............................................................................................................................ 25
5.5 Safety Issue: ........................................................................................................................... 25
Chapter 6 ...................................................................................................................................... 26
Conclusion and future outlook ...................................................................................................... 26
6.1 Future outlook ......................................................................................................................... 26
6.2Conclusion ............................................................................................................................... 26
Bibliography .................................................................................................................................. 27

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Chapter 1

1.1 Introduction of Andrew Paints

Andrew Paint Pakistan with its manufacturing facility in Islamabad has a dominant share in Industrial and
Aero Space coating business and is enjoying steady growth in decorative, refinish and architectural coating
markets.
With the establishment of Andrew Paints in Islamabad Pakistan, Andrew has introduced a whole range of
products including top coats, aero space coatings, refinish and decorative products. Andrew’s decorative
products were launched in 2007. Our decorative products include emulsions for interior and exterior, enamels,
pre-deco products, wood finish and texture paints

1.2 Project Scope

Learn the manufacturing process of Andrew Paint.

1.3 Research Purpose

The purpose of this research is to find out how process analysis takes place. What are the strategies
and procedure of manufacturing paints? To understand that basically what are the main factors they used to
keep in view while manufacturing and storing.

 Create and enhance value for the stakeholders through Growth and competitiveness.
 Reach status of supplier of choice for best Paint Industry in Asia.
 Create an exciting and safe work place for our employees.
 Reasons and Problems face during manufacturing .
 How to increase production with possible resources ?

1.4 Sources of Information

 Primary (through interview and visits )
 Secondary (official website)

1.5 Oriented Goals

Our goal is to find out the best practices of Process Analysis.

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1.5.1 Methodology

The data has been collected by means of primary data. The secondary data has been involved as well for some
of the data collection.

1.6 Research Procedure

The research has been conducted by visiting the departments of Andrew paints. Personal interviews from the
operations manager and industry manager were conducted for the collection of data of the research.

Some historical data is available in the form of annual reports, professional magazines and research reports.
However, the subject, being of strategic nature, required the descriptive or exploratory research to search the
effects of the existing policies and its implications.

1.6.1 Exploratory Research

Maximum possible information and knowledge has been gathered through an exploratory research. This was
achieved by the use of,

1. Authorized Company Sites

2. Personal Interviews
3. Newspaper

1.6.2 Interview
Personal interviews were conducted with the managers.

1.6.3 Interview Schedule

Open-ended questions were prepared and asked to the respondents .However, many of the answers given by
the respondents also became useful in creating new questions and exploring much other information which is
very useful for this study.

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Chapter 2:
2.1 Literature Review

The paint industry produces a huge variety of products that protect, preserve, and also beautify the objects to
which they are applied. Paint is generally custom-made to fit the needs of industrial customers. Typical
products include architectural coatings (e.g. house paints), industrial coatings (e.g. automotive finishes, wood
furniture and fixture finishes), and special purpose coatings (e.g. traffic paints, roof coatings). Paint is
composed of pigments, solvents, resins, and various additives. The pigments give the paint color, solvents
make it easier to apply, resins help it dry, and additives serve as everything from fillers to anti fungicidal
agents .Other Raw Materials which are being use in manufacturing are Chemicals which are used in the
production processes, and in the quality control laboratories for raw materials and products .Biocides are used
in the manufacture of the wood preservatives paints, and they are also used in the manufacture of water-based
paints. Detergents and antiseptics for floor cleaning .paints are used for interior and exterior house painting,
boats, automobiles, planes, appliances, furniture, and many other places where protection and appeal are
desired. All over the world the paint industries uses the same manufacturing process which includes.1:Making
of paste which includes that the manufacturer sends the bags of pigments to the plant then there the pigment is
mixed with one or more solvents. 2: Scatter the pigment. The pasted mixture is then send to the sand mill
which grind the pigment particles and then filtered to removed the sand particles. , the premixed paste is
subjected to high-speed shakeup by a circular blade attached to a rotating shaft. This blends the pigment into
the solvent. 3: Thinning the paste: the paste created by a sand mill or a dispersion tank, the paste must now be
thinned to produce the final product. Transferred to large tanks, it is up tight with the proper amount of
solvent for the type of paint desired. 4: Canning the paint. The finished paint product is then sent into the
canning room. Empty cans are first rolled horizontally onto labels, and then set upright so that the paint can be
pumped into them. A machine places lids onto the filled cans, and a second machine presses on the lids to seal
them. A certain number of cans are then boxed and stacked before being sent to the warehouse. Equipments
that are used in all over the paint industries are Mixers, Mills ( roller mills, ball mills etc), Filters, Packing
Machines(manual, semi-automatic, or automatic according to the size of production.) , Powder handling
(Dosing and handling transfer of powders) , Pipe pigging (multi-way valves, manifold, etc) the pipe pigging
technology has become a real process tool flexibilising the whole production unit: Paint manufacturers utilize

8
an extensive array of quality control measures. Packaging materials :( different types of packaging materials
are used (aluminum foil, metallic and plastic containers, tin sheets and cartons).The ingredients and the
manufacturing process undergo stringent tests, and the finished product is checked to insure that it is of high
quality. A finished paint is inspected for its density, fineness of grind, dispersion; Paint is then applied to a
surface and studied for bleed resistance, rate of drying, and texture. It is concluded that with the help of its
various tool box different units of paint manufacturing process has been designed. With an additional
monitoring and controlling the level of various tanks & controlling of mixer, valve & pump indications.

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Chapter 3
Paint and its Classification

3.1 What is paint ?

A liquid when applied on a surface or substrate by brush, spray, roller or dipping turns into a hard uniform
coating is called paint.

3.2 Main roles of any paint are:

1) Protection
2) Decoration.
3) Identification
4) Other Specialized Functions.

The paint industry in Pakistan operates both in organized as well as unorganized sector. There are around 20
big and small paint producing units in Islamabad, Pakistan. According to estimation, there are 150 units in
unorganized sector. Market size of paint in Pakistan is 2.7 billion annually. Demand for paint is 4 billion and
supply of paint is 2.7 billion. The paint industry consists of two segments namely:

1. Decorative segment --- caters to housing sector

2. Industrial segment --- consists of powder coating, floor coatings, and other proactive coatings
catering to the automobile, marine and other industries.

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 3.3 Paint’s Classification

Paint

Solvent
Water based based/Oil
based

Decorative Decorative Aerospace Industry

3.4 Quality policy

Andrew paint is committed to work within its customers to have a trust upon the organization in terms of
quality and have a better reputation in the market. For this purpose, Andrew paints will continually improves
its management and labor system through providing training to its employment and achieves the satisfaction
of customer.

3.5 Focusing our customer

We can guarantee our future only by giving our customers products and services that improve their future. So
this value comes first. It’s our priority and the reason why we exist. We’ve always met the needs of our
customers that is why we’ve grown.

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Chapter 4

4.1 PROCESS ANALYSIS:

Operations management at paints manufacturing company can be divided into these phases.

PRE PRODUCTION
PHASE

FORECASTING RAW MATERIAL

LOCATION
SUPPLY CHAIN HR PLANNING SCHEDULING
MARKET & INVENTORY
RELATED MGT
ISSUES

COST RELATED
ISSUES

1. Pre-production phase: that includes forecasting of sales, making availability of raw materials
2. Production phase: includes processing of raw material into a finishing good (manufacturing of paint)
and measures of quality control.
3. Distribution phase: it includes supply of paints to the market and ultimately to final customers.

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4.2 PRE-PRODUCTION PHASE
4.2.1 Forecasting
It includes forecasting of sales, profits, orders, costs and availability of labor to in order to meet the whole
requirement. In order to forecast the sales, Andrew has sales department that works for them quite efficiently.
Similarly different departments are working their jobs.

4.2.2 Location
Andrew was established in 2007. Its setup is at Triangle Industrial Area, Kahuta Islamabad. Location has to
do a lot with decisions of an organization which needs to be focused before selection of set up. Systematic
layout of industries matter a lot in production phase.

4.2.3 Human resource and job design

The work force at Andrew is round about 40 in one factory. It has sales, production and account department.
Work process of every department and individual is pre-determined. Sales department workforce brings sales
order by surveying market and also gets feedback from customers or retailers. They also do work of
marketing.

Accounts department keep record of all the costs occurring and within accounts department there is a finance
manager who estimates all funds needed. Likewise production dept performs all activities which they are
supposed to carry out. Within production department chemist prepares the chemical formula for
manufacturing paints and distemper and also determine the ratio in which every material is added. Some
labors operates machine and some are performing work which is need to be done manually. Few workers are
supposed to fill the gallons and do packing.

4.2.4 Scheduling
Production scheduling consists of the activities performed in a company in order to manage and control the
execution of a production process. At Andrew fixed scheduling is assigned correspondingly form each worker
group to each task with a specific machine in continuous production. On the basis of demand manager can
change the output of each period, for that scheduling of each product will be changed. The quantity of task
and time has been set in a way that no worker gets bored and gives their maximum.

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4.3 What is in a Can of Paint?
The paint raw materials are listed on the product along with instructions about how and where to add them.
Raw materials can be divided into four main groups:

Pigment: to color the paint, control gloss, prevent

corrosion, add bulk
Binder :to stick the paint together, form a film and
give adhesion.
Solvent: to make paint useable.

Additives: to do all the little, but important jobs.

Pigments

True Pigments Extendors

Provide hiding
Give colour Fillers give the paint body / make
Provide anti-corrosion the paint bulky and improves flow
properties ( i.e. less sagging on application).

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4.3.1 Some Pigments are:

Calcium Carbonate, Talcum, Aluminum Silicate, China Clay, Titanium Dioxide , Thalo Blue etc

Pigments are finely ground crystalline solids that are dispersed/ suspended in the paint. They may be organic,
in-organic and metallic.

4.3.2 Binders:

 Make the coatings adhere to the surface.

 Provides Gloss to the coatings.
 Hold the Pigment in suspension.
 Provide resistance to water, chemicals, and abrasion.

e.g Alkyd resin , Acrylic , PVA

4.3.3Additives:

Drier Speeds up the drying

Thickener Provide thickness
Thixotropes Alter the rehology
Silicones Alter surface properties
Anti-skinning Agent Prevent skinning in the Can
Plasticizers Give flexibility to paint film

4.3.4 Solvents:
Solvent makes paint easier to apply

Provides correct application and film properties

They are used to reduce the viscosity of paint for better flow & application.
E.g. Water, turpentine Oil (MTT) , White spirit , Xylem , Butyl Acetate , Acetone
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4.4 Process Flow Diagram of Water Base Paint

Fig4.4.1 Process diagram of water base

16
4.5 Process Flow Diagram of Oil Base Paint

4.5.1 Process Diagram of Oil Base

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4.6 Keeping and storing of different raw material are in:
1) Drums

2) Plastic bags

3) Paper pads

4) Lining shopper

5) Large canes

This includes both powder form chemicals and liquid chemicals. Every chemical come in its own packing and
they are kept in the same packing, the temperature changes and the storing place is same where production is
done. Pigments that are used in paints are in powder form, it becomes in paste form after converting it in
colors. Raw materials in powder form have no life limit it usually has long life and they can be kept for
lifetime, they don’t change and remain in its powder form. One important thing is they keep it away from
water because water destroys its form. Pigments have no expiry date.

4.7 Temperature:
The normal keeping and storing temperature is 25-35 degree. The normal chemicals don’t need as such any
special treatment they are kept on the normal temperature as given. But there are few special raw materials
that need some special treatment there temperature vary as what is the chemical. They are mostly kept on 30
degree not above than this.

4.8 Issues of Raw Material

 A lot of raw material is wasted because of less space and miss management.
 Iron oxides may be encountered as dust from paints, dyes and colorants used by the Paint
Department as it is used as a pigment in these products
 Pigments' powder are stored outside which causes dust.
 Solvents cause serious human health effects. It may cause minor eye, skin infection.
 Purchasing and wastage of raw material affects a lot on production and cost.

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 Fig4.8.1 Pigments powder

Fig 4.8.2 Pigment powder storage

19
 Fig 4.8.3 Solvent and binders opened in heat

4.9 Kaizen Rule for Raw Material:

 Specific rooms should be design to place raw material and Output Products
 Raw material should not be purchased in bulk if rooms are not available.
 Keep product drums tightly closed when not in use.
 Prevent product containers from being damaged.
 Keep Material containers in a well ventilated area .

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Chapter 5
5.1 The Manufacturing Process of Paint Industry:

5.1.1 Making the paste

Pigment manufacturers send bags of fine grain pigments to paint plants. There, the pigment is premixed with
resin (a wetting agent that assists in moistening the pigment), one or more solvents, and additives to form a
paste.

5.1.2 Dispersing the pigment

The paste mixture for most industrial and some consumer paints is now routed into a sand mill, a large
cylinder that agitates tiny particles of sand or silica to grind the pigment particles, making them smaller and
dispersing them throughout the mixture. The mixture is then filtered to remove the sand particles.

Instead of being processed in sand mills, up to 90 percent of the water-based latex paints designed for use by
individual homeowners are instead processed in a high-speed dispersion tank. There, the premixed paste is
subjected to high-speed agitation by a circular, toothed blade attached to a rotating shaft. This process blends
the pigment into the solvent.

5.1.3 Thinning the paste

Whether created by a sand mill or a dispersion tank, the paste must now be thinned to produce the final
product. Transferred to large kettles, it is agitated with the proper amount of solvent for the type of paint
desired.

5.1.4 Canning the paint

Paint is filled in cans manually with the help of jars.

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 5.2 Manufacturing Process of Andrew Paints

5.3 Problems Occurs During Manufacturing Process

 Sometimes mixer stops working and paint gets thick.
 Bottleneck occurs due to Location of machinery.
 Starving due to the slow speed and manual work of High Shear Mixer because it makes the paint
dry

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5.3.1 Kaizen applied:
 If mixer stops working then keeps the attritor on normal speed.
 If the Mill mist gets thick stabilize it by keeping it on slow speed and add the mixture for thinness
of paint.
 Kaizen must applied.
 Must Increase number of helpers on each machine.

5.4 Machines Used In manufacturing the paint:

5.4.1 Attritor
 Attritors are energy efficient, compact, easy to operate, and require low maintenance.

 Advantages:

 Versatility: Attritor’s design allows modification of numerous variables to adjust changing

specifications and meet the final product requirements.

 Reduced Transportation Costs: In many wet slurry processes, 50% of the gross weight is liquid.

5.4.2 High Shear Mixer

PROS:

 Mixes fluids having higher viscosities

 High Strength

 The degree of mixing and dispersion invariably affects a variety of characteristics, such as:

• color

• gloss

• conductivity

• Stability.

23
5.4.3 Tinting

Fig 5.4.4 Tinting Cans

 Tints are lighter than hues and are formed by adding white to the colors on the color wheel.

5.4.5 Issue:
The main issue on a tinting machine is maintenance.

5.4.6 Kaizen Applied:

The machine is not well maintained and should be serviced every six months. The nozzles should be
cleaned on daily basis, because it is impossible for a poorly maintained machine to tint accurately

24
5.4.7 Canning
Issue: Use manual fillers to fill the cans. Which cause wastage of time.

Kaizen:

 By bringing the new technology

 time can be consumed
 Less work load for workers

5.5 Safety Issue:

25
Chapter 6
Conclusion and future outlook

6.1 Future outlook

Industry Leaders Should come with more innovations and has a positive outlook in the coming years.

6.2Conclusion
Note that a poor or adulterated raw material and a wrong manufacturing process will never produce a good
product hence usage of new technology and quality checks on raw materials and finished products are very
essential in order to get the desired benefits from such products. Quality checks of every steps says a lot about
the image of any organization. Above all the quality of a product should NEVER be compromised.

26
 Bibliography

1) https://www.slideshare.net/ChristopherBoote1/painting-process-analysis-and-improvement
2) http://www.madehow.com/Volume-1/Paint.html
3) https://www.slideshare.net/yagrawal2/paint-manufacturing-process
4) http://www.resene.co.nz/whatispaint.htm
5) http://www.freepatentsonline.com/5087645.html

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