TECHNICAL PRESENTATION

(TSS Meet Dec'22 , 2018)

Presented by:

Umesh Yadav

Rishikesh Pandey
(TSS Haldwani)
Content:
1. VA-VE/ Kaizen activity

2. Problem resolution

3. New product trial

4. Competitor activity

5. CRM score
E activity : ACED bus bar modification to reduce DFT variation f
by cost saving
(Badve Engg.Pantnagar)
Before

Deposition of coating on Frame body was taking

place in partial dip condition and half of the frame
body getting more deposition time & result in higher
DFT on bottom side of frame body.
 After
Excess bus bar is covered with teflon sheet (to isolate
excess bus bar) and now coating on frame body starts in
full dip condition, result in more uniform of DFT
distribution on top and bottom side of Frame body.
Observation (after modification)-
> Finish and appearance found Ok.

> DFT DATA (before and after busbar

modification)
DFT DFT
Location
Before
After(modification)
Frame body Top 24 24
Frame body middle 27 26
Frame body bottom 31 28
Average DFT 27.3 26
micro
Reduction in average DFT 1.3
n
Hence, % reduction in DFT 4.75 %
Paint saving (after ED busbar
modification)
After busbar modication DFT variation reduced and over all average DFT
reduced upto 1.7 micron followed by paint saving as below:

Monthly paint consumption (avg)

19500 (F1&F2)
kg
Monthly paint saving in
926 (F1&F2)
kg
Paint cost (F1&F2)
202.25 Rs/kg
Rs/kg
Monthly cost saving in Rs.
187284 1.87 lac
(Estimated)
Annual cost saving in Rs.(Estimated) 2247000 22.47 lac
Annual cost saving
Rs 22.47 lac/month
A-VE activity : Jig modification to increase productivity an
generate cost saving.
( Badve Engg. Ltd ACED
Line)
Before After
One 'Battery carrier' was Now after hanger modification
being loaded on Jig for aced 2 'Battery Carriers' are being
coating loaded for ACED coating
 Cost saving after Jig modification:
ACED Plant running cost per hour 10000 Rs
Production in JPH 129 Nos
Plant running cost per Jig 77.52 Rs/Jig
Battery carrier production per day 150 Nos
After modification No of Jigs saved per day 75 Nos
Hence , cost saving after Jig modification 5813.95 Rs/day

Monthly cost saving after jig modification 145348.84 Rs/month

Monthly cost saving

= 1.45 lac/month
A-VE activity : Jig modification to increase productivity an
generate cost saving.
( Badve Engg. Ltd ACED
Line)
Before After
4 Nos of parts (Air tank Now after Jig modification 8
support) was being loaded Nos. Of parts (Air tank
per Jig for aced coating. suport) are being loaded per
Jig for aced coating
 Cost saving after Jig modification:
ACED Plant running cost per hour 10000 Rs

Plant capacity in JPH 129 Nos

Plant running cost per Jig 77.52 Rs/Jig

Battery carrier production per day 150 Nos

After modification No of Jigs saved per day 19 Nos

Hence , cost saving after Jig modification 1472 Rs/day

Monthly cost saving after jig modification 36821 Rs/month

Monthly cost saviing is

36821 Rs/month
 Problem Resolution –(Ashok
Leyland)
Line issue-
Water marks on B pillar, >60 % ED coated cabins were
observed with this issue.
Cause:
Water marks on B pillar was due to water logging in door seam
causing water drops on B pillar during baking.

Door jig
to hold
door in
place
Trial done to resolve the issue :
(a) ED final DI water rinsing spray pressure increased to ensure door seam
cleaning- Slight improvement observed
(b) Manual DI water spray with hose pipe and manual air blow- No
improvement observed
(c) Increased the gap between door and B pillar by modification in door jig---
Issue resolved

Modified
door clip
Problem Resolution –
Leyland)
Before:
Paint drop issue on window and
A- pillar from rain channel, due
to excessive sealant application
and high DFT.
(Ashok
After:
Training given to Top Coat
painters to optimize DFT. Sealant
width is also reduced.
Problem Resolution – (Ashok
Leyland)
Line issue:
•There was orange peel issue on B pillar area and rest
of cabin was ok.
•Due to this issue 100% rework ( polishing) was
being done. Gap between
door and B
Causes: pillar

•Low DFT on B pillar area

•During robot painting paint was not
reaching B pillar area due to gap
between door and B pillar
•Door clip dimension was not
proper
Problem Resolution – (Ashok
Leyland)
Counter measure taken:

•Modification done in G91 topcoat door clip to

reduce the beween door and B pillar
•Check point added in daily check sheet, ensure
that operator must be aware it
New door clip old door clip
Result : Orange peel issue minimized after door clip
modification as per below image.
 KAIZEN ACTIVITY – (Ashok
Leyland)
Before After
In topcoat painting, there Now we are doing manual
was issue of paint miss in painting on fixture fitment
boss cabin on fixture fitment before topcoat painting to
area. avoid miss paint.
 KAIZEN ACTIVITY – (Ashok
Leyland)
Before After
Low lux level in ED sanding Now new LED tube lights are
and inspection zone causes installed to maintain desire
difficulty in identifiying lux level.
defects.
NEW PRODUCT TRIAL: (Ashok leyland Pantnagar)

PRODUCT : RAPID CURE BLACK

CUSTOMER : Ashok leyland ltd PNR

EXISTING SUPPLIER : M/S- NIPPON PAINTS

• We have successfully done trail of Rapid cure black at M/s-

Ashok leyland Ltd.

• Total 15 Nos of chassis body were painted and sent for

detailed observation.

• Please refer to attached MOM.

 Competitor Activity

1. Berger paint has submitted shade panels and 1 litre of

stoving Casablanca white sample for testing ( Nov-18)

2. PPG Asian had also submitted shade panels and white

paint sample for testing and is now approved source for
supplying white paint.(April-18)

3. Berger paint is also approching our ED customer and

offering low cost CED and free initial fill.
 Mahindra Jaipur improvment points
( Report submitted to customer)
Sl No Issue Observation Suggestions

- Paint peel off observed with -Rust/dried oil contaminants must be

Paint peel off charcoal grey. removed before PT with the help of emery
issue observed - Some VTU housing observed paper and suitable cleaner.
1 near gear shift with touch up/repainting of - Sludge/powder must be cleaned before
area and VTU top charcoal grey. painting as it weakens bonding between
- Sludge formation on machining surface and paint
parts

Paint peel off on -Contamination observed on

2 front axel RH front axel RH after PT Manual cleaning of front axel RH to be
side done before PT

- Average DFT on some location - Adjustment of gun flow rate done to

3 Excessive DFT of chasis observed high as 180 optimize DFT.
on chasis ~200 micron

Sludge and -Sludge formation observed on Manual cleaning started before primer
4 powdery PT over all chasis after PT painting
coating
 CRM score :

Tss
Name- Umesh Kumar Rishikesh Pandey
Month Actual/Target % Actual/Target %

April -18 450/450 100% 350/350 100%

May -18 450/450 100% 350/350 100%

June -18 450/450 100% 350/350 100%

July -18 440/450 98% 350/350 100%

Aug -18 450/450 100% 350/350 100%

Sep -18 420/450 100% 300/350 86%

THANK YOU !!