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    This document provides a summary of painting pre-treatment parameters and measurements taken at PT. SGMW Motor Indonesia over a 3 week period in May 2018. Key stages included deluge, pre-degreasing, degreasing, water rinses, surface conditioning, zinc phosphate, more water rinses, and final DI water rinses. Measurements were within specifications for temperature, pH, alkalinity, conductivity, and other parameters across the various stages of the painting pre-treatment process.

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    This document provides a summary of painting pre-treatment parameters and measurements taken at PT. SGMW Motor Indonesia over a 3 week period in May 2018. Key stages included deluge, pre-degreasing, degreasing, water rinses, surface conditioning, zinc phosphate, more water rinses, and final DI water rinses. Measurements were within specifications for temperature, pH, alkalinity, conductivity, and other parameters across the various stages of the painting pre-treatment process.

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    56 views27 pages

    378088

    Uploaded by

    mbotstore karawang
    This document provides a summary of painting pre-treatment parameters and measurements taken at PT. SGMW Motor Indonesia over a 3 week period in May 2018. Key stages included deluge, pre-degreasing, degreasing, water rinses, surface conditioning, zinc phosphate, more water rinses, and final DI water rinses. Measurements were within specifications for temperature, pH, alkalinity, conductivity, and other parameters across the various stages of the painting pre-treatment process.

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    of 27

    PT.

    SGMW MOTOR INDONESIA


    PAINTING - PRE-TREATMENT

    MONTH May YEAR 2018


    WEEK 1 2 3 X 4 5

    Monday Tuesday Wednesday Thursday Friday Saturday


    Stage Parameter Units Specification Date : 14 Date : 15 Date : 16 Date : 17 Date : 18 Date : 19 Remarks
    1st 2nd 3rd 1st 2nd 3rd 1st 2nd 3rd 1st 2nd 3rd 1st 2nd 3rd 1st 2nd 3rd
    Deluge
    Temperature °C 45° ~~ 55°C 46.0 45.5 46.6 46.3 45.7 46.3 46.1 46.4 45.9 46.4 46.1 46.4 46.0 45.8 46.4 46.0 45.3 45.9

    Temperature °C 50° ~~ 55°C 50.7 50.6 50.8 50.9 51.0 51.2 50.9 51.0 50.9 51.0 51.1 51.0 51.2 50.9 50.9 51.3 50.9 51.1
    GC S5176
    Pre - Degreasing Total Alkaline pt. (Tal/Fal) ≤2.5 2.42 2.08 2.43 2.48 2.50 2.48

    Free Alkaline pt. 8.0 ~~~ 12 8.4 8.7 8.4 8 9.7 8.9 8.4 8 8.4 8.4 8.7 8.6 8.2 8,4 8.5 8 8.2 8.3
    GBA H7354/1
    pH pH 9.5 ~~~ 12 10.7 10.7 10.7 10.6 10.9 10.8 10.9 10.8 10.9 10.9 11 10.9 10.80 10.80 10.7 10.6 10.8 10.8

    Temperature °C 50° ~~ 55°C 51 51 51 51.1 51 51 51.2 51 51 51 51 51 51.4 51 51 51.2 51 51.1


    GC S5176
    Degreasing Total Alkaline pt. (Tal/Fal) ≤2.5 2.25 2.30 2.20 2.33 2.38 2.42

    Free Alkaline pt. 8.0 ~~~ 12 8.6 8 8.4 8.0 8.2 8 8.3 8.1 8 8.1 9.2 8.3 8.0 8.1 8 8.0 8.2 8
    GBA H7354/1
    pH pH 9.5 ~~~ 12 11 11 10.9 10.9 10.9 10.9 11 11 10.9 11 11.2 11.1 11.1 11.1 11.1 11.1 11 11

    pH pH 7.5 ~~~ 11 9.6 9.1 9.2 9.6 9.2 9 10 9 9 9.3 9.1 9.3 9.4 9.2 9 9.5 9.1 9.2
    Water Rinse 1
    Accelerant pt. 2.0 ~~~4.0 3.9 3.1 2.8 4.6 3.9 3.1 4.3 3.9 3.1 4.5 3.5 3.2 4.2 3.6 2.9 4.4 4.2 3.3

    pH pH 7.5 ~~~ 11 9.5 9 9.2 9.4 9.4 9.3 9.7 9.2 9.1 9.4 9.2 9.2 9.4 9.3 9.1 9.3 9.2 9.2
    Water Rinse 2
    Accelerant pt. 2.0 ~~~4.0 3.6 3 2.5 4.4 3.6 3.2 4 3.3 2.9 4.6 3.4 3.2 4.1 3.5 2.7 5.4 4.8 3.6

    Surface Conductivity µs 1000 ~~~ 3000 1032.0 1114.0 1120 1264.0 1287.0 1283 1421.0 1411.0 1395 1529 1536 1543 1678.0 1705.0 1718 1882.0 1883.0 1882
    GN VP4528
    Conditioning
    pH pH 8.5 ~~~ 10.5 10.2 10 10.1 10.9 10.2 10.1 10.1 9.8 9.8 9.8 9.9 9.8 9.6 9.5 9.3 9.2 9.1 9..2

    Gardobond 24TA Temperature °C 41° ~~ 45°C 46.1 41.1 41.7 40.1 41.3 42 40.0 41.2 42 41.2 41.9 41.7 40.7 41.7 42 40.2 41.6 41.5

    Gardobond 24TE Free Acid pt. 0.8 ~~~ 1.3 0.9 0.8 0.8 0.8 1.0 0.9 1.0 0.9 0.9 0.8 1.1 1.1 0.9 0.9 1 0.8 0.9 1
    Zinc
    Phosphate GBA H7001 Total Acid pt. 18 ~~~24 22.2 22.0 21.5 21.3 22.8 22.1 21.7 21.7 21.6 21.3 22.7 22 21.8 21.9 21.5 20.6 21.6 21.5

    GBA H7101 Accelerant pt. 3.0 ~~~ 6.0 4.5 3.6 5.2 5.2 4.1 3.4 5.4 4.7 4.1 5 3.4 4.5 5.9 4.7 3.7 4.7 3.7 4.2

    GBA H7256 Slag ppm ≤ 500 131.7 165.5


    Water Rinse 3 City Water pH pH 4.5 ~~~ 7.5 8 7.2 7.4 6.9 6.5 6.1 6.6 5.6 5.3 5.3 4.7 4.6 4.4 4.4 4.3 4.4 4 4.2
    Water Rinse 4 City Water pH pH 6.5 ~~~ 7.5 8 7.8 8 7.9 7.2 7.5 7.4 7.1 7.1 6.8 6.8 7 6.4 6.4 6.2 6.1 6.2 6.2

    pH pH 6.5 ~~~ 7.5 7.3 7.2 7.2 7.00 6.50 7.1 7,3 6.7 7 6.7 6.9 7.1 6.4 6.7 6.8 6.30 6.20 6.1
    DI Water 1 DI Water
    Conductivity µs ≤60 6.1 6.8 6.2 5.7 6.7 6.9

    pH pH 6.5 ~~~ 7.5 7.2 6.7 6.9 6.8 6.2 6.7 7 6.5 6.8 6.4 6.4 6.8 6.8 7.1 6.7 6.3 6.4 6.4
    DI Water 2 DI Water
    Conductivity µs ≤30 7.9 4.4 4.1 6.9 8.9 6.4

    pH pH 6.5 ~~~ 7.5 6.6 6.6 6.4 6.8 6.6 6.6


    Drip (Door Sil1)
    Conductivity µs ≤30 5.0 5.2 5.5 5.8 5.3 6.7

    Grade 2 RO pH pH 6.5 ~~~ 7.5 7.4 7.2 7.4 6.5 6.8 7.1
    DI Water
    Water
    Conductivity µs ≤10 4 3.9 5.3 3.6 5.4 10.7
    Degreasing OK OK OK OK OK OK
    Appearance
    Phospating Film OK OK OK OK OK OK

    ITEM Chemical Content Remarks

    Gardolene VP 4528 75 8 8 9 8 8

    Gardobond Additive H7354-1 100 100 100 100 50 50

    Gardoclean 10037-2
    PPF : 0000 REVISION : 0024TE3
    Gardobond DATE : / / 2018 DCR NO : 140 140 70

    Gardobond Additive H7001 102.5 31 61.5 10.25 61.5 61.5 20,5 61.5 61.5 20.5

    Gardoclean S5176 133 61.5 41 246 61.5 133 123 133 133 184.5
    Chamical
    Gardobond Additive H7256
    Gardobond 24 TA
    Gardobond Additive H7101
    Gardobond Additive H7107
    Gardobond Additive H7143
    Gardobond Additive H7211 20 20 20 20 20 20

    REMARKS :

    APPROVED BY : CHECKED BY PPG

    VERIFY BY SGMW
    BULAN : 13
    DAILY CONTROL PARAMETER Free Alkaline of Pre Degreasing

    12

    11

    10

    7
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MIN MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MIN 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
    MAX 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
    ACT 8.6 8.5 8.3 8.133 8.3 8.3 8.5 8.866 8.266 8.566 8.366

    Total Alkaline/Free Alkaline Ratio of Pre Degreasing


    3

    2.5

    1.5

    0.5

    0
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MAX 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
    ACT 2.42 2.32 2.48 2.48 2.45 2.5 2.42 2.08 2.43 2.48 2.5
    BULAN :
    DAILY CONTROL PARAMETER Free Alkaline of Degreasing
    13

    12

    11

    10

    7
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MIN MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MIN 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
    MAX 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
    ACT 8.033 8.5 8.2 8.266 8.15 8.15 8.333 8.066 8.133 8.533 8.033

    Total Alkaline/Free Alkaline Ratio of Degreasing


    3

    2.5

    1.5

    0.5

    0
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MAX 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
    BULAN :
    DAILY CONTROL PARAMETER

    ACT 2.34 2.37 2.4 2.48 2.4 2.37 2.25 2.3 2.2 2.33 2.38

    Conductivity of Surface Conditioning


    3500

    3000

    2500

    2000

    1500

    1000

    500
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MIN MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MIN 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
    MAX 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000
    ACT 1017.3 1243 1379 1522 983.5 1368.5 1088.6 1278 1409 1536 1700.3

    pH of Surface Conditioning
    11

    10.5

    10

    9.5
    pH of Surface Conditioning
    BULAN :
    11 DAILY CONTROL PARAMETER
    10.5

    10

    9.5

    8.5

    8
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

    MIN MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MIN 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5
    MAX 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5
    ACT 10.333 10.466 10.1 10.333 10.4 9.8 10.1 10.4 9.9 9.833 9.466

    Free Acid of Phospate


    1.5
    1.4
    1.3
    1.2
    1.1
    1
    0.9
    0.8
    0.7
    0.6
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MIN MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MIN 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
    MAX 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3
    ACT 0.966 1.0333 0.9 1.0333 0.85 0.9 0.833 0.9 0.933 1 0.933

    BULAN :
    DAILY CONTROL PARAMETER Accelerant of Phospate
    6.5
    6
    5.5
    5
    4.5
    4
    3.5
    3
    2.5
    2
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MIN MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MIN 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
    MAX 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
    ACT 4.566 4.533 4.2 3.8 5.65 4.2 4.433 4.233 4.733 4.3 4.766

    Conductivity of Drip Water


    35

    30

    25

    20

    15

    10

    0
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MAX 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30
    ACT 18.4 5.5 5.1 4.2 7 4.8 5 5.2 5.5 5.8 5.3

    BULAN :
    DAILY CONTROL PARAMETER pH of Drip Water
    8

    6
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MIN MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MIN 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5
    MAX 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5
    ACT 7.1 7 6.3 7 7.2 7.1 6.6 6.6 6.4 6.8 6.6

    Conductivity of Fresh RO
    12

    10

    0
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MAX 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
    BULAN :
    DAILY CONTROL PARAMETER

    ACT 4.2 3.8 4.6 3.2 4.3 5 4 3.9 5.3 3.6 5.4

    pH of Fresh RO
    8

    6
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
    MIN MAX ACT

    Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
    MIN 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5
    MAX 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5
    ACT 7.2 7 6.9 6.2 7.1 7.6 7.4 7.2 7.4 6.5 6.8
    f Pre Degreasing
    BULAN :
    DAILY CONTROL PARAMETER

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    MAX ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    8 8 8 8 8 8 8 8 8 8 8 8 8
    12 12 12 12 12 12 12 12 12 12 12 12 12
    8.166

    ne Ratio of Pre Degreasing

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    X ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
    2.48
    of Degreasing
    BULAN :
    DAILY CONTROL PARAMETER

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    MAX ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    8 8 8 8 8 8 8 8 8 8 8 8 8
    12 12 12 12 12 12 12 12 12 12 12 12 12
    8.066

    aline Ratio of Degreasing

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    X ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
    BULAN :
    DAILY CONTROL PARAMETER

    2.42

    urface Conditioning

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    MAX ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
    3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000
    1882.3

    e Conditioning
    e Conditioning
    BULAN :
    DAILY CONTROL PARAMETER

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

    MAX ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5
    10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5
    9.166

    of Phospate

    1447

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    MAX ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
    1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3
    0.9

    of Phospate
    BULAN :
    DAILY CONTROL PARAMETER

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    MAX ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    3 3 3 3 3 3 3 3 3 3 3 3 3
    6 6 6 6 6 6 6 6 6 6 6 6 6
    4.2

    of Drip Water

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    X ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    30 30 30 30 30 30 30 30 30 30 30 30 30
    6.7

    rip Water
    BULAN :
    DAILY CONTROL PARAMETER

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    MAX ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5
    7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5
    6.6

    y of Fresh RO

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    X ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    10 10 10 10 10 10 10 10 10 10 10 10 10
    BULAN :
    DAILY CONTROL PARAMETER

    10.7

    resh RO

    16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
    MAX ACT

    19 20 21 22 23 24 25 26 27 28 29 30 31
    6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5
    7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5
    7.1
    No. Issue Analysis

    1 Overflowed phospath bath Still on investigation

    Slightly high coating weight


    2 Still on investigation
    and crystall size of CRS

    Oil separator system did not work properly.


    3 Pin holes on fender The level is low.
    Oil separator system did not work properly.
    3 Pin holes on fender The level is low.

    Rusty on rear left wheel


    4 Air pocket
    house

    Leaked on pump for phospat Broken seal


    5 dosing tank A
    Action Owner Due Date
    1. Flush both clarifier tank every morning
    before the production start2
    2. Checking and callibration the pressure
    gauge of sediment pump
    3. Cleaning filter strainer of phospat
    4. Reset the takt time of phospat system to
    initial setting
    5. Trial run the phospate system without cars
    6. Monitor daily increment of phospat level

    SGMW

    1. Do another check for coating weight and


    SEM to confirm the problem. Chemetall 31st May
    2. Confirm with SGMW China for the
    specification of coating weight and crystall SGMW
    size

    Add more water to oil separator system


    SGMW 15th May
    Spray phospate solution to that area
    (Temporary solution) SGMW 17th May
    Need to find permanent solution

    Replace the seal


    SGMW 14th May
    Remark

    Graphic is available on the next sheet

    SGMW Need to ensure that all the equipment are working properly before start
    the production
    SGMW Need to ensure that all the equipment are working properly before start
    the production

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