Defect reduction in vintage car repainting

Abstract

To reduce blistering/solvent boil defective and dust contamination defective in vintage car repainting. From the research, the both defect rates are 100% that the major causes of the defects result from dirty equipment and wrong using of equipment and material that cause waste in rework cost in terms of both time and expense including re-inspection cost. These 5 steps are exercised in this research including defining phase, measurement phase, analysis phase, improvement phase and control phase respectively. This research studied in details of the production process to find factors that cause both defects in the measurement and analysis phases. The main factors were selected and analysed by Failure Mode and Effect Analysis (FMEA) Then, those factors were tested by statistic and found the suitable parameter settings of the process by Design of Experiment (DOE). Having found the appropriate parameters, the process was controlled to protect reoccurrence problems. After the improvement of painting processes, it is found that the blistering/solvent boil defect is reduced 81.5% and dust contamination is reduced 59.02% of the defect before the improvement.