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COURSE
PROGRAM
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(08:00-08:10)
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Greetings
by K. Saito - Director of PTC and IIR4D
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(08:10-09:50)
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Changes in Automotive Painting - I
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by K. Toda
Fundamental mechanism of the quality issues:
Atomization, Solvent Evaporation, Viscosity Change,
Film Thickness vs. Transfer Efficiency,
Appearance Quality
Changes in the application equipment:
(Electrostatic) Spray Gun, No.2 Process Bell,
Mini-Bell, Metallic Bell, Multi-feed Bell, Cartridge Bell
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(09:50-10:00)
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Morning Break
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(10:00-11:50)
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Process Improvement Tools: CFD and Applications - I
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by A. J. Salazar
Introduction to Computational Fluid Dynamics (CFD):
Engineering analysis and traditional approaches, CFD approach,
Basic steps in CFD analysis
Application of CFD to Paint Overspray Capturing:
Problem identification, pre-processing, solver execution, post-processing
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(12:00-01:00)
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Lunch Break
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(01:00-03:00)
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Process Improvement Tools: Applying the Toyota Production System Approach to Paint Shop Defect Reduction
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by S. Doyle
Creating a comprehensive approach:
Benchmarking process conditions, analytic methodologies,
Jishuken approach to problem solving,
Strategies for maintaining team member involvement
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(03:00-05:00)
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Changes in Automotive Painting - II
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by K. Toda
Changes in the automatic application system:
Reciprocator, Old Robot Painting, Modular Robot Painting, New Robot Painting
Reduction of VOCs emissions, energy usage:
Difference between Japanese and American/European way,
Kaizen: Continuous improvement
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(08:00-09:50)
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Changes in Automotive Painting - III
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by K. Toda
Application of Waterborne Paints:
Evaporation rate of water, rheology control,
Electrostatic spray equipment for waterborne paints
Application of Powder:
Mechanism of powder coating, Transfer efficiency and paint recovery,
Paint delivery system
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(09:50-10:00)
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Morning Break
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(10:00-11:50)
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Process Improvement Tools: CFD and Applications - II
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by K. Kuwana and A. J. Salazar
Application of CFD to VOC's calculation:
Problem identification, pre-processing, solver execution,
post-processing
Applcation of CFD to sprayer cup simulation:
Problem identification, pre-processing, solver execution,
post-processing
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(12:00-01:00)
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Lunch Break
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(01:00-03:00)
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Process Improvement Tools: NDT and Applications
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by M. Omar
Introduction to Non-destructive testing (NDT) in Painting:
Basic concepts, terminology, traditional inspection techniques,
UV surface inspection, infrared thermography
Applcations of NDT to industries:
Automotive industry, marine protective coating, composite materials
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(03:00-05:00)
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Changes in Automotive Painting - IV
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by K. Toda
Compact Coating Process in the Plant Site:
Rastatt, Mazda, Daihatsu/Toyota, Others
Future
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Course Program: Painting Technology Application Process Improvement
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