Free Audit Painting Plant

Audit and Modification of Paint Shop study is laborious and time consuming before arriving at a decision. For the free audit to be effective, customers must send the following information — all items are absolutely essential:

• 1
  Existing Painting Process — Submit internal process documents describing the current painting process, paint types, cycle times and production flow.
• 2
  Photograph for Each Equipment — Provide clear photographs of every piece of equipment in the paint shop — spray booths, ovens, conveyors, pretreatment tanks etc.
• 3
  Layout Drawing of Existing Equipment — The plant layout drawing showing the floor plan, equipment positions and flow of material through the paint shop.
• 4
  Existing Production & Required Production — How much is the existing production volume and how much production is required — in components per shift or per day.
• 5
  Quality Problems — Give a detailed list of all quality problems currently experienced in the paint shop — rejections, finish defects, dust contamination, adhesion failures etc.
• 6
  Copy of All Drawings & Instruction Manuals — All available equipment drawings and instruction manuals — if available — to be shared for reference during the audit.
• 7
  Financial Audit (Optional) — If a financial audit is required, please submit cost input data — including paint consumption, energy costs, rejection losses and manpower costs.

Consultancy Painting Plant (Comprehensive)

All Audits are designed to find out the present as well as potential problems in a Paint Shop. The Audit Report specifies the deviations in the Paint Shop performance with respect to the designed parameters. Based on the report, an action list can be drafted — helping in taking necessary steps for trouble-free operation of the Paint Shop at the designed efficiency.

Audits can focus on addressing current issues and suggest improvements — comprehensive consultancy will cover all of the following:

Painting Plant Consultancy – Revamping & Modification

All Paint Shop Consultancy for revamping and modification is a specialised and more complicated subject — handled exclusively by Technical Director Mr. Umesh Prabhu with 40 years of valued experience. Autocoat has successfully commissioned large Painting Plants involving dismantling, shifting, upgradation, re-erection and commissioning. These plants are in operation even after 10 years of dismantling and re-erection (after earlier use of 10 years) at very nominal cost of revamping.

Consultancy for Revamping / Modification (Renovation of Existing Painting Plants) is structured in two phases:

Consultancy Painting Plant – Imported Equipment

In India, during past years many companies have imported Painting Plants and Powder Coating Plants from their collaborators. It is very expensive to run such plants at lower capacity or through a foreign agency. There is a great need for a reputed consultant who is already experienced — able to guide, suggest and locate vendors to maintain and operate such process plants without any stoppage.

Consultancy for Imported Equipment will include guidance on the following four areas:

• 1
  Spares Availability Since this is a continuous process plant, any stoppage is directly related to output from the plant. There are many critical items — conveyor, pumps, heat exchangers, blowers, filters etc. — especially when the life of the plant used by the parent company is more than 5 years. Autocoat guides on identifying and sourcing these spares in India.
• 2
  Cost of Different Applications Generally such plants are customised as per output and process to optimise for the original application. If such an imported plant is used for a different application in India, it is likely to incur more costing. Autocoat provides guidance on optimising the plant for the new application at the lowest possible cost.
• 3
  Cutting Operating Cost Guidance to cut down operating cost because of large variety and dynamic product mix — including production control techniques to save on LPG, chemical cost, powder cost and other operating costs.
• 4
  Upgradation Guidance Consultancy will include guidance on upgradation — detailed study required to identify and add additional plant as needed. For more details on upgradation, refer to Autocoat’s Revamping / Modification Painting Plant service.

Frequently Asked Questions