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paint shop project

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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 )
Protecting our planet is a group project
2003 Earth Award
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 .
Protecting our planet is a group project
2003 Earth Award
PROJECT GOAL
Overview cont.
INPUT : Liquid LDO
Target : Consumption
Reduction
Thermic fluid heating
system (Thermax Plant)
Heat
INPUT: Electricity
for Air curtain ,
air circulation
& chemical
circulation
Heat
Degreasing ( 2 tanks )
Rinsing ( 2 tanks )
Baking
Oven
Phosphating ( 1 tank )
Rinsing ( 1 tank )
Passivation ( 1 tanks )
Drying oven
BAKING OVEN
PRE TREATMENT PLANT
Protecting our planet is a group project
2003 Earth Award
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
Phosphating plant
Drying oven
Heat
Loss
Heat
Loss
Baking Oven
Painting of parts
Plastic parts
Output
Protecting our planet is a group project
2003 Earth Award
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 .
Input LDO
+
Electricity
Phosphating plant
Heat transferred
through mechanical
valve
Drying oven
Residual heat
Heat
Loss
Baking Oven
Plastic parts
Painting of parts
Output
Baking eliminated by usage of air dry paint
hence reduce usage of baking oven
Protecting our planet is a group project
2003 Earth Award
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 .
Protecting our planet is a group project
2003 Earth Award
RESULTS AND BENEFITS
34 % Reduction
47 % Reduction
2.5
400
1.77
2
326
10
300
0.93
1.5
29 % Reduction
215
7.6
8
5.4
6
200
4
1
100
2
0.5
0
0
0
Yr.'2001
Before
Yr.'2002
LDO consumption in Ltr / per m/c
Yr . 2001 = 1.77 Ltr/ per m/c
Yr. 2002 = 0.93 Ltr / per m/c
After
Cost of PU paint
Earlier = Rs. 326 per Ltr
After = Rs. 215 per Ltr. (Air Dry)
SAVING
Yr.'2001
66 % Reduction
35
TOTAL LDO SAVED IN Yr. 2002
TOTAL ELECTRICITY SAVED IN Yr. 2002
= 7190 Ltr
= 18.8 kWH
MONETARY SAVING( in Yr. 2002)
= $ 4430
Yr.'2002
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
28
24
21
14
8
7
0
Earlier
After
Cycle time of PU paint parts
Earlier = 24 hrs
After = 8 hrs.
Protecting our planet is a group project
2003 Earth Award
TEAM MEMBERS
TEAM MEMBERS
• ABHAY DEEP
• ASHOK SHARMA
• AMIR NISHAT
• ZAFAR KHAN
• BABU KHAN
• MUNEER KHAN
• MANOJ KR. DAS
Protecting our planet is a group project
2003 Earth Award
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