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Safety checks
- Gloves, protective glasses and ear plugs are to be worn throughout this operation.
- Keep hands and clothing away from moving parts at all times.
SAFETY
- Ensure to wear ear protection when working in noise zone area.
- Open shoes are prohibited on factory premises.
- All necessary PPE to be worn when working in spray booth.
- Gloves to be worn when removing frames from the line required.
ENVIROMENTAL
- Ensure all lights are in good working condition.
- Report any gas leaks immediately to Supervisor / Workshop.
- Report any chemical spillage to supervisor / Workshop.
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PLANNING
1. Receive the route card from production planning department.
2. Draw epoxy powder from stores department.
3. Receive Rods from Production 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 the 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.
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CLEANING PROCESS
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1. Lift up trolley using the hoist and submerge it in the CHEMCLEAN tank and leave basket for 10-15 minutes. Temperature should be between 50° - 60°.
2. Lift up trolley using the hoist and submerge into Rinse tank for 1 minute.
3. Lift up the trolley using the hoist and submerge it into the PHOSKRO P tank for 10-15 minutes.
4. Lift up trolley using the hoist and submerge into Rinse tank for 1 minute.
5. Lift up the trolley using the hoist and submerge into PHOSKRO 901 (Phosphate) for 7-12 minutes.
6. Lift up trolley using the hoist and submerge into Rinse tank for 1 minute.
7. Put trolley into PASSIVATE tank for 1 minute to dry parts.
8. Check oil and dirt on products visually before loading the line.
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LOADING ON CONVEYOR
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1. Check for defects on the wires.
2. Load 8 Rods on to the hangers
3. Use painting jigs to hang the Rods as per picture
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POWDER COATING
1. Start spraying the Rods , make sure each Rod is covered completely with Epoxy Powder
2. Make sure Epoxy Powder does not drip on the ends of the Rods
3. Avoid using an excessive powder which could cause dripping during the curing process
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CURING PROCESS
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1. Continue the curing process through the conveyor oven. Rods to stay in the conveyor oven for 20 min
2. Check you curing samples as per your Process Check schedule (QD115/03/13)
3. If not correct, repeat the curing process for the entire line
4. If correct, start removing the Rods when cooled, from the line for inspection (touch up if necessary)
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LINE FIRST OFF
1. Check samples for Epoxy coating finish as per In process Logsheet (QD75/04/13). Record on BIS Card
NO : Quarantine Rods in holding area, notify Supervisor and await disposition.
YES : Retain the Rods 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.
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FINAL INSPECTION
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1. Check that each Rods Hoods is coated properly.
2. Visual check for burrs on swing wire
3. Check for poor /no coating on the Rods
4. Refer to the relevant boundary sample and record all findings on the F/A Sheet (QD152/02/14) and powder thickness on B.I.S Card
5. Attach traceability stickers to Rods at specified place.
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