SAFETY  

• Gloves, protective glasses and ear plugs are to be worn throughout this operation.

• Keep hands and clothing away from moving parts at all times.

1. Ensure to wear ear protection when working in noise zone area.
2. Open shoes are prohibited on factory premises.
3. All necessary PPE to be worn when working in spray booth.
4. Gloves to be worn when removing frames from the line required.                                                                                

ENVIROMENTAL

1. Ensure all lights are in good working condition.
2. Report any gas leaks immediately to Supervisor / Workshop.
3. Report any chemical spillage to supervisor / Workshop.

CALIBRATE THICKNESS GAUGE

First calibrate thickness gauge (Elcometer), never do a thickness test without calibration. Thickness gauge calibration is complete by doing the following:

3.1 Use thickness gauge test plate (metal plate) to do the calibration, ensure plate is clean by rubbing it on a clean cloth.

3.2 Place thickness gauge on test plate.

3.3 Remove thickness gauge from test plate, if reading is “0” the thickness gauge is calibrated.

3.4 If not on “0” then press and hold the “-“ button on the gauge for 5 seconds , then continue to press until the value goes down.

3.5 To check if gauge is calibrated place back onto test plate ,gauge must read “0” , if not re-calibrate and follow steps 3.2 – 3.5.

3.6 Place gauge on steel plate and ensure it is on “0”.

3.7 Place gauge on foil plate marked as 50 , read value. Reading should be between 48.5 – 51.5.

3.8 Should the reading be out of the tolerance , press and hold either “-“ or “+” for more than 5 seconds , adjust the foil value either up or down till it reaches 50 , place on steel plate to zero and check value again.

3.9 Place gauge on foil plate marked as 125 , read value . Reading should be between 121.25 – 128.75.

3.10 Should the reading be out of tolerance , press and hold either “-“ or “+” for more than 5 seconds . Adjust the value either up or down till it reaches 125 and place on steel plate to zero , check value again.

COATING

1. Receive the route card from production planning department.

2. Draw epoxy powder from stores department.

3. Receive Rod Hoods from Seat Assembly dept

4. Verify the oven setting. It must be between 190deg. C – 200deg. C

5. Verify your conveyor speed. It must take approx. 43 – 45 seconds per meter. The conveyor is marked 1 meter.

6. Clean the spray booth to get rid of any old powder.

7. Make sure that your spray gun is clean before filling with required black epoxy powder.

8. Check and verify your spray gun setting: Powder Flow 1 – 2, and Air 1 – 10

9. Do the Chemical Test as per WI 38, and record results on QD329/02/21.

10. The curing time is as following 190 degrees for 12 minutes or 200 degrees for 10 minutes to acheive a    good coating.

11. Continue the curing process through the conveyor oven. Frames to stay in the conveyor oven for 20          min.

13. If not correct, repeat the curing process for the entire line.

LINE FIRST OFF INSPECTION

1. Check samples for Epoxy coating finish as per In process  record on BIS Card.

NO : Quarantine Parts in holding area, notify Supervisor and await disposition.

YES : Retain the Parts as the First Off Sample until the completion of batch when it will be added to the final packaging of products.

2. The final batch sample is to be kept and used to verify your new first off.

CHECK COATING THICKNESS

4.1 Do 1 first Off, use thickness gauge (Elcometer) to read thickness and record readings on BIS Card. Thickness to be between 80 -125 microns. 4.2 Take reading as per picture below and record measurements for each batch on the BIS card 4.3 Do reading on 1 Rod per batch. 4.4 Send trolley with boxes to moulding station. 4.5 Pack first-off in the last batch 4.6 Do last-off from the last batch 4.7 Keep last off to verify the first-off