1、常见的涂层缺陷、成因 及修复方法,现象 附着力缺失： 层间分层：涂层与涂层之间 与底材的分层：底漆与底材之间: 原因 底漆与后续涂层不兼容 底材或涂层之间存在污染物 覆涂间隔时间过长 粉化/渗出 修复 清除松动油漆层或清除至底材 重新施工涂层,分层（附着力缺失）,关闭,底漆,喷砂清洁的钢材,面漆,氧 湿气 污染物,面漆,层间分离,喷砂清洁的钢材,分层（附着力缺失）,关闭,从焦油环氧上剥落,Flak spant 0590 - 39,醇酸从锌粉涂层上剥落,Gjerde flaker 1-8,覆涂间隔过长造成剥落,Flaking alu.mal. 0590 - 38,粉 化,关闭,粉 化,关闭,粉化
2、,失 光,关闭,失 光,关闭,失 光,4226-0066,0807-47,渗出和碳化（胺渗出）,关闭,渗出和碳化（胺渗出）,C22/2-17,C22/2-19,黏手及发亮的表面,黏手及白色表面,点 锈,关闭,点 锈,关闭,针 孔,关闭,底漆,喷砂的钢材,湿面漆,溶剂/空气,针孔,针 孔,关闭,起 皱,关闭,起皱,喷砂钢材,起 皱,湿面漆,底漆,关闭,举 起,关闭,举 起,关闭,干 喷,关闭,施工中产生的漆雾,底漆,喷砂的钢材,干 喷,关闭,干喷 显微镜观察状态,Snitt dryspray 0589 - 58,渗 色,关闭,白色面漆含焦油底漆喷砂的钢材,失色渗色,渗 色,关闭,渗 色,橘子皮,
3、关闭,橘子皮,关闭,橘子皮,流挂和熔挂,关闭,流挂和熔挂,关闭,鱼 眼,渗透作用,多孔性,渗透作用,溶剂残留,不恰当的油漆施工,涂料中成分析出（诸如：焦油、固化介质等）,盐份,有亲水溶剂造成的吸水,溶剂挥发后残留空泡,底漆,表面处理后残留在底材上,导致电化学腐蚀。传输离子（电渗透）,阴极剥离，丧失附着力,腐蚀,水泡,增加了水蒸气的渗透性,起泡成因,关闭,解决问题的途径,Built-In Quality 制造质量,不断改进,员工参与,标准化,缩短制造周期,制造质量,Built-In Quality 制造质量,Built-In-Quality 制造质量,What Is Quality?什么是质量？
4、 Group Discussion小组讨论,Definitions 定义,Quality is what the customer perceives to be acceptable to achieve his/her enthusiasm质量是客户感觉能够接受并满足其热忱的东西,Mad Cow 疯牛 (Diseased Meat 病牛肉),Poor Quality Means Lost Sales 质量差意味着失去客户,Firestone 燧石 (Unintended Accidents) 意外事故,uninstalled shift lock 漏装移位锁定 (Sudden Accele
5、ration) 突然加速,Built-in-Quality 制造质量,What is Built-In-Quality?什么是制造质量？ Group Discussion小组讨论,What is Built-In Quality? 什么是制造质量？,Definition 定义Method by which quality is built into the manufacturing process, so that defects are prevented, detected, and countermeasures are implemented to prevent reoccurre
6、nce. 指质量在生产过程中产生，因此可以预防、发现缺陷，以及采取措施防止缺陷再发生的方法。Purpose 意图 Ensures defects are not passed to the customer. 确保不传递缺陷。,Designers 设计师,Suppliers 供应商,Production 生产人员,Dealers 经销商,Buyers 采购员,Sales & Marketing 销售人员,The Customer Chain. . . Company Perspective 客户链 公司远景,Built-In-Quality 制造质量,Assembly 总装,Supplier
7、供应商,Paint 涂装,Body 船体,The Customer Chain. . . Production Perspective 客户链 公司远景,Each Process Has at Least One “Customer” and One “Supplier” 每个阶段至少有一个客户和一个供应商,Built-In-Quality 制造质量,Do not 不要,a Defect! 缺陷,Solve Problems Through Teamwork! 团队合作解决问题！,Built-In-Quality Motto 制造质量口号,Satisfy Your Customer 满足你的客
8、户,Living up to the Motto. . . 符合口号. . . - What Is a Defect?什么是缺陷？Group Discussion 小组讨论,Defect 缺陷,A defect is a product that does not meet the established quality standard. 缺陷是不合已定标准的产品。,Measurement of a quality characteristic 质量性能测量,Vehicle # 车辆 号,Upper Specification Limit 规格上限,Lower Specification L
9、imit 规格下限,Quality Standard 质量标准,Defect 缺陷,Defect 缺陷,x,x,Why are defects undesirable? 为什么缺陷不受欢迎？,Defects may also result in 缺陷还可能导致High warranty costs 过高保修成本Lost customer sale 失去客户,Defects Require Correction = Correction is Waste缺陷需要纠正纠正就是浪费,QUALITY IS EVERYONES RESPONSIBILITY 质量是每个人的职责,Design, Engin
10、eering, Production, Quality, Support Departments and Suppliers.设计，工程，生产，质量，相关部门及供应商OUR Best Resources: 我们最好的资源: PEOPLE 员工OUR Goal : 我们的目标： Everyone is a Quality Inspector 人人都是质检员 Everyone is a Problem Solver 人人都是问题解决者,Reflect voiceof the customer 反映顾客的心声,Simple, clear& support user 简单、清晰， 有利操作者,Clea
11、rly Measurableat point of use 在使用上可明确测量,Key Points of Good Quality Standards: 质量标准的要点：,In users Std. Work& posted visual在操作者的标准化 工作或张贴出来,Standards MustSupport the Operator, too Not only the Engineer! 标准不仅有益于设计者， 也有益于操作工人,Not tighter thanthose applied at theprevious process不要比前道工序的更严格,Key Points of G
12、ood Quality Standards: 质量标准的要点：,Use master parts andboundary samples as required to make visual 标准件与边界样件需要目视化,Key Points of Good Quality Standards: 质量标准的要点：,Boundary Samples shouldvisually indicate OK Not OKcondition to help operatorsmake quick, good decisions 边界样件应该标明好或不好，以便 操作人员迅速且更好地下决定。,Visually
13、 “describing” the defectis Not a Boundary Sample! 目视化标明缺陷不是边界样件！,Create a “Standards-Based” Culture 创造一个以标准为基点的文化氛围,Talk in terms of The Standard, not opinions! 以标准为基点，而非观点！,4) DefectEscalation 缺陷逐层汇报,Escalate defects toleadership for supportdepending onfrequency and criticality! 根据缺陷出现频率与严重程度 逐层向领导
14、汇报以寻求支持！,In-Process Control & Verification 2) DETECTION,Detection,Example:,Team Leader,Section Leader,Group Leader,2 defects/ 1 hour,4 defects/ 1 hour,1) Use Andon(taught more later) 使用暗灯,Make problems visual& pull in support! 问题直观， 拉线寻求帮助！,In-Process Control & Verification 3) CONTAINMENT,Always Rem
15、ember the Priorities:一定要牢记： 1) Safety安全 2) Quality质量 3) Responsiveness (Throughput)响应,Containment 包容,2) FollowContainmentProcess 遵循包容程序,Extraordinary actions to prevent defects from being passed! 采取特别行动防止 缺陷传递！,In-Process Control & Verification 3) CONTAINMENT,Some examples: 1) Stop the line停线 2) 100
16、% checks 100%检查 3) On-line repair 线上维修 4) Reworks返工 5) Sorting 整理,Containment 包容,How Does our Quality Motto relate to Containment?,Do not 不要,a Defect!缺陷！,It means empowered leaders makejudgments how to control qualitywhile trying to keep the line running! 意味着领导有权作出决定：在尽量不停线的情况下， 怎样控制好质量！,Does this m
17、ean we stop the line every time we have a problem? 这是不是意味着一有问题就停线呢？,How Does our Quality Motto relate to Containment?,Sometimes the best decision may be to let a defect pass to the next process, but有时最好的办法是让差错转到下工序，但是 It is a conscious decision made by the appropriate level Action must be communicat
18、ed to next “customer” Defect must be clearly identified on vehicle Containment must be in place to prevent further defects,Examples of Some Andon Guidelines: 暗灯使用的指导方针 1) Will the problem affect the next process? 问题会不会影响下道工序？ 2) Can I effectively repair the defect out of station? 能不能在工位外有效解决问题？ 3) W
19、hat is the status of my decouplers? 自己的切断器是什么状态？ 4) Others 其他,“Customer” 客户,Quality Information Feedback/Feedforward 质量反馈与前馈,“Suppliers” 供应商,You 你,Process A Process B Process C,back,Defect flowing from A to B缺陷从A流到BStatus on Problem Resolution问题解决状态,forward,Escaped defect flowing to Process C避免缺陷流到C
20、 Temporary process being used in Process B过程B的暂时方案 Process/product change with time 工艺/产品随时间改变 Status on Problem Resolution问题解决状态,Motivation for Timely Feedback 及时反馈的动机,Immediate 1 Day 1 Year High Medium Low 1s 100s 1000s,Time to Discover Defect 发现缺陷的时间,Ability to Discover Root Cause 发现根源的能力,Number of Defective Vehicles Built 已经生产的缺陷产品,谢谢,
