Process Improvement for Underbody Anti-Corrosion Coating Spray: A Case Study at an Automotive Manufacturer
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Abstract
The researcher investigated the operation of the automotive underbody anti-corrosion coating production line and found that the current process exhibits issues of paint film sagging and overspray deposition on the vehicle body surface. These defects cause disruptions in subsequent production stages, leading to machine downtime. The objective of this research is to establish standardized work procedures in the production line, reduce operational problems, and minimize coating material costs. Data were collected from all stages of the coating spray process, after which the root causes of problems were analyzed using the Why-Why Analysis technique. The development of standardized work instructions, with the spray gun pressure set and controlled at 80 bar. Furthermore, the procurement plan for coating materials was revised to achieve greater efficiency. As a result, the underbody anti-rust coating process in automotive manufacturing became more effective.
The results of the improvement in preventing underbody anti-rust coating flow indicate that, prior to the modification, 10 vehicles encountered this issue in October 2023. After the implementation in December 2023, the number of affected vehicles was reduced to zero, representing a 100% improvement. The number of defects observed at the fender area decreased from 27 cases to 6 cases after improvement, corresponding to a reduction of 77.78%. For the hood area, the number of defects decreased from 15 cases to 0 cases, achieving a 100% reduction. Additionally, the spray gun pressure standard was controlled at 80 bar. Furthermore, the problem of excessive procurement of coating material was addressed. The purchase quantity was reduced from 188 kg to 153 kg after the improvement, corresponding to a reduction of 18.62%. The overall improvement outcomes reflect the effectiveness of the measures in both process quality enhancement and efficient utilization of resources.
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References
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