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TEAM NAME. Team Name : TEAM PAINT SHOP. Contact no : 91- 595 - 2357152. Nominator information : Abhay Deep Mail : ( abhay.deep@ind.xerox.com ) . Primary Contact : Iqbal Khan Mail : ( Iqbal.khan@ind.xerox.com ). PROJECT GOAL. Project Goal :.
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TEAM NAME Team Name : TEAM PAINT SHOP Contact no : 91- 595 - 2357152 Nominator information : Abhay Deep Mail : ( abhay.deep@ind.xerox.com ) Primary Contact : Iqbal Khan Mail : ( Iqbal.khan@ind.xerox.com )
PROJECT GOAL Project Goal : • Reduction of Natural Resources Usage ( Low Density oil ) • Reduction in Power Consumption Overview: • XIND Paint shop has conveyorised spray type pre-treatment plant having 7 tank process followed by drying oven . • Wet spray painting is used for both Metallic and plastic ( ABS ) parts . • Baking oven is used for baking of painted parts . • Both Pre-treatment plant & drying oven are heated through close loop Thermic fluid heating system ( Thermax plant ) for which input is liquid LDO ( Low density oil ) . • Air / chemical circulation , air curtain , blower etc. are driven through electricity .
PROJECT GOAL Overview cont. INPUT : Liquid LDO Target : Consumption Reduction Thermic fluid heating system (Thermax Plant) Heat Heat Degreasing ( 2 tanks ) Rinsing ( 2 tanks ) INPUT: Electricity for Air curtain , air circulation & chemical circulation Baking Oven Phosphating ( 1 tank ) Rinsing ( 1 tank ) Passivation ( 1 tanks ) Drying oven BAKING OVEN PRE TREATMENT PLANT
HOW WAS THIS ACHIEVED HOW WAS THIS ACHIEVED Process : Before • LDO is used to heat drying oven of pre-treatment plant & Baking oven . • Plastic( ABS ) parts are painted and are baked in baking oven . • Metallic parts are phosphated , dryed , painted and then baked Input LDO + Electricity Heat Loss Phosphating plant Drying oven Heat Loss Baking Oven Painting of parts Output Plastic parts
HOW WAS THIS ACHIEVED HOW WAS THIS ACHIEVED Process : After • Residual heat of drying oven used to heat Baking oven . • No baking of Plastic parts . Heat transferred through mechanical valve Input LDO + Electricity Phosphating plant Drying oven Residual heat Partly heat diverted from drying oven Heat Loss Baking Oven Plastic parts Painting of parts Output Baking eliminated by usage of air dry paint hence reduce usage of baking oven
RESOURCES AND TIMING RESOURCES • XIND Paint supplier • With help of our paint supplier , various paint samples were developed and tryout were conducted to get desire quality . • XIND Paint shop team • Paint shop team observe that residual heat of Pre-treatment plant used to get waste so they fitted mechanical valve by operating which , heat is getting transferred to baking oven. • Since initial firing of Oven consume lot of consumable ( LDO ) . Hence paint shop team increased batch size to minimize this consumption. TIMING : • JAN ‘02 • Fitting of mechanical valve to transfer residual heat. • To optimize batch size • MAY-JUNE ‘02 • Development of air dry paint . • Trial and tryout on paint and cut-in for production .
29 % Reduction 66 % Reduction 47 % Reduction 34 % Reduction RESULTS AND BENEFITS Power consumption ( paint shop only ) in unit / per m/c Yr . 2001 = 7.6 unit/ per m/c Yr. 2002 = 5.4 unit / per m/c LDO consumption in Ltr / per m/c Yr . 2001 = 1.77 Ltr/ per m/c Yr. 2002 = 0.93 Ltr / per m/c Cost of PU paint Earlier = Rs. 326 per Ltr After = Rs. 215 per Ltr. (Air Dry) SAVING TOTAL LDO SAVED IN Yr. 2002 = 7190 Ltr TOTAL ELECTRICITY SAVED IN Yr. 2002 = 18.8 kWH MONETARY SAVING( in Yr. 2002) = $ 4430 Cycle time of PU paint parts Earlier = 24 hrs After = 8 hrs.
TEAM MEMBERS TEAM MEMBERS • ABHAY DEEP • ASHOK SHARMA • AMIR NISHAT • ZAFAR KHAN • BABU KHAN • MUNEER KHAN • MANOJ KR. DAS
