Process standardization for car interior paint production: a comprehensive study on the paint production transfer from Offenbach to Barcelona

Abstract

This project centers on relocating car interior paint production from the Offenbach factory to Barcelona, with a strong emphasis on process and product standardization and optimization. The transfer of production is a process that must be done with careful consideration to ensure successful manufacturing and obtain both a standardized process and product. First, the components of the paint and its production process are explained to provide context and a foundation for the comprehension of the project. It also delves into the types of paint utilized depending on their intended purpose and briefly outlines the quality control procedure, including various laboratory tests and materials used. Secondly, the experimental part is divided into two sections: process and product standardization. To standardize the process, a study of the equipment and the production process has been made to develop various SOPs (Standard Operating Procedure). The SOP provides detailed step-by-step instructions to correctly manufacture each product, and it explains the cleaning procedure for the equipment and the packaging, ensuring a consistent product across batches. Product standardization begins with the manufacturing of the first batch for each paint reference. In this phase, a series of tests have been conducted in the laboratory to fine-tune parameters such as pH and viscosity. The application process in the cabin has also been defined by selecting the appropriate application program based on the experimental tests, and considering requirements such as the visual aspect and the thickness of the paint layer. Once the program is defined, the protocols undergo validation in the laboratory, and other parameters, such as brightness, are adjusted. After collecting the initial data for each reference and properly adjusting each batch, this project concludes with the reformulation of each product to ensure the desired results in the next batch manufactured.