Technology: an effective way to improve coating production efficiency

Coating production is a highly automated production The production of a finished product starts from the last part, goes through a series of processes such as degreasing, phosphating, cleaning, drying, powder spraying, curing, etc until the next part It is a systematic and continuous process The workpiece runs at a uniform speed on the production line, and no pause point is allowed in the middle, which is the most important part of the coating production line Basic production characteristics Because of the above basic characteristics of coating production, the production capacity of coating production depends on the production line itself When the design scheme of a coating production line is determined, especially when the running chain speed of the production line is determined, its maximum production capacity is basically determined Because, after the operation chain speed of coating production is determined, the effective processing time of each processing process on the production line and the scope of relevant process requirements must be determined accordingly, and the scope of adjustment is generally not too large In the actual production, through our research and many attempts, we found some effective ways to improve the efficiency of coating production After practical use, the effect is very obvious 1 Starting from the coating of hanging appliances, improve the utilization rate of hanging appliances The hanging appliances used in the coating production of our company can be said to have experienced the following three routes of improvement: (1) complete set of hanging appliances → single piece of hanging appliances When the production line was first introduced from Japan, it was all copied from Japan The hangers for painting were also designed to be suitable for the whole set of production Generally, a set of air conditioning shell can be hung completely with one hanger This kind of hanging device is very effective in the ideal production organization state, but in the actual production, most of the workpieces cannot be prepared in complete set, so there are often many hanging points idle on the hanging device For this reason, we have changed the complete set of hanging appliances into a single piece of hanging appliances to improve the effective utilization rate of hanging appliances (2) special hanging appliances → concurrent hanging appliances After the change from complete set of hanging appliances to single piece of hanging appliances, although the effective utilization rate of hanging appliances has been improved, with the increase of production varieties, the problem of frequent replacement of hanging appliances in the production process has been exposed quickly Considering the convenience of the use process, after a large number of design trials, we have improved most of the hanging appliances to dual-use hanging appliances One hanging appliance can be used for several workpieces In this way, the problem of frequent replacement of hangers in the production process has been well solved (3) Number of hangers: 2 → 4 → 6 → 8 or 16 In the process of the above two improvements, we have increased the hanging point of a single hanging device by scientific design of the hanging device, under the condition of ensuring that the hanging point is not more than the bearing capacity of the hanging point, so as to greatly improve the effective utilization rate of the hanging device, and some even increase the utilization rate several times, so that the actual production capacity of the coating line body has greatly broken through the design and production capacity Through the improvement of the above three lines, the production efficiency and production capacity of the coating production line are greatly improved, so that the coating production is no longer the bottleneck factor restricting the production expansion of our company 2 In actual production, we also use new coating pretreatment chemicals to improve production efficiency In the past, we used traditional coating pretreatment agents The use temperature of degreaser and phosphating agent is required to be above 50 ℃, and each shift needs a long time of heating process before production, especially in the cold weather in winter, sometimes it can not reach the set temperature for a long time, which affects the normal operation of production Later, we used a new type of low-temperature phosphating agent and degreasing agent, which greatly shortened the heating process In addition, the new phosphating agent has the characteristics of low slag, which reduces the time of cleaning tank slagging, facilitates the production management, increases the effective working time, and improves the production efficiency Not only that, because of the low use temperature of the new coating pretreatment agent, the energy consumption is greatly reduced and the production cost is saved, which can be said to be a good thing with more than one stroke 3 Improve the equipment and increase the spare tank In the peak season of production, the coating production line also runs 24 hours a day Due to the increase of production, the tank solution in the degreasing tank and pre degreasing tank often needs to be replaced in a few days, and the replacement tank solution also needs to use part of the normal production time In order to ensure the quality of the product and not delay the normal production time, we modified the line body Beside the original degreasing tank and the pre degreasing tank, a parallel degreasing tank and a pre degreasing tank were connected In this way, no matter when we change the bath solution, we will not affect the normal production time We just need to prepare another bath solution in advance This is also an effective way to improve production efficiency The above points are some small experiences we have summed up in the actual coating production, but they are effective methods Why not invest less and earn more!