KIN RAILWAY EQUIPMENT PVT LTD

MML3 Paint damages & Poor touch up

issue

Date/Month – Jan-2024
Ceiling panel Hook mark touchups from Customer end

KIN comments
In the Powder coating process, parts are hanging by the
"Hooks" in the powder coating booth for the earthing
connectivity.
So, after powder coating process, Manual paint
touchup will be done on the hook marks locations, It is the
Universal standard process followed in all the projects
from the FAI.
 Ceiling panel Hook mark touchups from Customer end
After Powder coating Hook mark location After Paint touch up
(Before Paint touch)

Hook mark location after

powder coating. Powder
not covered in the hook Manual paint touchup will
butting areas be done after oven curing
 In ceiling panels, Hook marks touchup observed

- For all the powder coated parts Fresh Hooks only should be used.
- After powder coating the manual touch required area will get minimized.

The hook mark intensity can be reduced, But cannot be eliminated.

Need AT Expertise support for alternate solution if Manual touchups are not allowed.
 Paint touch ups reported from Customer end

Manual paint touchup being done for minor aesthetics issues

 Improvements taken to avoid the damage in Internal Handling

10.00 Rubber permanently fixed in all the “A”

stands,
20.00 mm Foam fixed as a additional
protection

After painting parts are protected with stretch film (Before Rubber material (10.00 mm) Foam protection implemented
wrapping paint touch-up and curing ensured). After protection & Foam (30.00mm) placed in Skeleton phase assembly
film wrapping, cloth packing done to avoid any scratches and over the A-stand to prevent
damages during Internal movement paint surface direct contact
during assembly
 MML3 Paint damages, Scratches and Improper Touchups action plan
Sl.No Process Problem description Action plan
After painting parts are protected with stretch film (Before wrapping paint
1 Powder coating
touch-up and curing ensured)
In powder coating process, after inspection part may got damage
In future cloth packing planned after painting -working with PE for quick
2 Powder coating
implementation
For all the powder coated parts Fresh Hooks only should be used. Hook
3 Powder coating In ceiling panels, Hook marks improper touchup observed
mark intensity can be reduced, But cannot be eliminated.
Part may got damage in the "A" stand which is used for holding the ceiling in Rubber material & Foam placed over the A-stand to prevent paint surface
4 Assembly
the assembly process direct contact during assembly
5 Assembly Skeleton stage inspection need to be performed by Quality.
Painted surface got damaged during the Internal Handling & Improper Paint
touchup observed at many locations. Cloth protection to be implemented in all the semifinsihed parts (Skeleton
6 Assembly
stage, Assembly stage)
Process sequence optimised and No of rotation reduced to 2 times from 4
7 Assembly Damages may happened during the ceiling modules roatation during Assembly
times.
Assembly stage wise Manpower need to fixed,
8 Assembly Continious changes in the Man power
List need to shared. (Including all the sub-activity).
Material may got damaged during the movement from Powder coating to For containment, At kitting store part will be checked by Quality and will
9 Assembly
Assembly be given to Quality.
Regular refreshment training have been conducted for assembly workers
10 All process
on proper handling techniques
Disciplinary actions (Suspension) will taken to the Operator for all the
11 All process Mishandling of the parts by the Operator
Mishandling of parts.
Strictly adhered use of gloves while assembly and metal wearing's
12 All process
avoided for assembly personnel
Dock audit to be performed for next 20 Ceilings and report need to be
13 Packing Scratches observed during incoming at AT
share
Scratches reported from Customer end
Scratched reported in the Ceiling panels at AT Incoming.

KIN Comments :
1) All the Ceiling panels are checked by KIN QA on 100% frequency.
2) After Internal clearance, All the parts are checked by AT-QW in 100%
frequency
3) After AT-QW clearance, immediately Primary packing will be done in
front of Quality
4) Parts are dispatched in the returnable trolley only,
5) We have taken clear Photos/Videos before the dispatch, We have not
identified any scratches at our end.

NEED CFT DISCUSSION WITH AT

Thanks