POWDER
COATING
PROBLEM
CONTENTS
• 1. Problem description
• 2. Where is the issues were noticed ?
• 3. Potential Root Causes for the problem.
• 4. Activities planned
• 5. Constrain at supplier
Problem Description:
Due to material damage, we are frequently observing powder coating peeling off at our assembly line, see below
pictures. Damaged coating portion on part are not constant, so the source of impact is untraceable.
Where were the problems found?
This issue mostly found at final assembly line, defect never observed in received powder coated material.
1. Wrong process flow : Machining ,Vacuum impregnation & anodising process doing after powder
coating process. (use of harsh chemicals & acids to prepare surface in vacuum and anodising
process )
2. Excess & improper material handling: Machining ,Vacuum impregnation & anodising process
we are doing after powder coating process from outside, over material transportation.
3. Raw material i.e. Poor powder quality: Wrong storage condition of powder is deteriorate
powder quality, changes in powder source frequently leads most of powder coating problems.
4. Moisture on surface : Die casting material has tendency to undergo natural corrosion forming a
thin layer of zinc oxide or zinc carbonate on the surface which we commonly call as white rust. This
material is porous, hence must be properly dried after pretreatment. We are storing castings at rotex
and have FIFO issue.
5. Appropriate pretreatment : Every material has different pretreatments mainly
• Pretreatment for MS : Seven stage treatment.
• Pretreatment for aluminium : Six stage treatment.
• Pretreatment for Galvanized sheet: Eight stage treatment
• Pretreatment for Aluminium die casted material :four stage treatment.
6. Man dependent pretreatment :Currently we have four stage manual pretreatment at our vendor.
1. Alkaline Degreasing :
2. Water rinse:
3. Chromating:
4. Water Rinse:
7. Drying process : This material is porous, hence drying very crucial for coating ,must be properly
dried after pretreatment. Water / moisture is directly linked with bonding of powder & base surface,
life of powder coating.
8. Curing process : Oven temperature & time monitoring completely manual man dependent.
(operator aware of 210 degrees Celsius for 30 to 40 minutes) Improper curing time Or temperature
leads peel off issue.
Activities planned :
[Link] we are observing problems in Black powder, as discussion of supplier for such small
volume requirement difficult to develop & procure powder from BRANDED powder mfg.
currently we are using Marpole powder, so we can order market available similar high-quality powder from reputed
sources. (Proposal pending at Sharma ji for approval).
[Link] powder storage facilities necessary at vendor to maintain quality & life of powder in recommended storage
condition.
[Link] need to develop powder at best source of powder with our required grade and finish, this could possible when we
procure material from large volume powder coating applicator.
[Link] need to follow by Rotex store during issuing material for powder coating process.
[Link] complete control on each stage surface pretreatment, drying ,powder application, curing.
Constrain at supplier :
1. Unavailability of competent technical person to monitor & maintain process control currently completely dependent
on labor.
2. Man dependent operations, (Need PLC controlled conveyer pretreatment plant at supplier).
3. Not capable to procure & stock RM (powder).
4. 100% inspection from competent inspector required at supplier.