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Hirata
Engneering Consulting Office
(HEC)
--Consultant specialized in coating field-- |
Defect of a paint coating surface
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The introduction of the technical consultant to Coating Diagnosis.
Profile of President Hirata
-Name ; Seiji Hirata born at 1957 (56 years old)
-Address ; Kumagaya-shi,Saitama,Japan
-Licence; Consulting Engineer (Japanese National License)
Specialty;dust particle reduction, air flow diagnosis, painting environment
analysis
- On-going contract; 15 companies in Japan, 2 companies in South Korea.
-Future target; Complete Zero defect from seeding and dust in the industry
coating field.
1. Mission
My mission is to challenge the complete Zero defect for the coating problems.
Seeding and dust problems at the coating process are the major causes of
the increase in the coating process cost.
We will determine the causes of dust and seeding problems taking the highly
sensitive detection methods and instruments.
We clearly visualize the causes of dust and seeding problems by taking
the several visualizing equipments.
Through visualization, we can show to the customers the current real situation
what is really happening at the coating envirionment, not what may be happening
of coating place, by visualizing the causes of these problems.
These problems can not be solved by the haphazard
procedure.
We can teach our clients precisely the effective and cost-efficient steps
to reduce defect.
We can do so because we have the abundant know-hows of visualizing the
mechanism of the problems that happening.
Our desire is to contribute to the growth and the higher profit of the
customers by offering the clear solution of the countermeasure for the
coating problem.
2. The menu of the consulting
A) The guidance of the countermeasure for seeding and dust problem
caused by the floating dust in coating place.
----------to clearly visualize the real causes by taking the right equipment
of Green laser, and Particle sensor for the rough seeds so on.
B) The guidance of the countermeasure for the seeding and dust problem caused by the seeding or dust in the paint container.
--------to visualize the paint seeding or dust sprayed out from spray gun
nozzle.
C) The guidance of the countermeasure for the poor appearance caused by
the substrate itself.
--------to check by my long experience based on the engineer knowledge at the metal parts company which process the several
metal like the wrought metal and cast metal.
D) The guidance of the countermeasure for the seeding and dust problem
at Electro Deposition coating plant. ( visualization of the dust which
can not be seen by human eye.)
E) The guidance of the countermeasure for the seeding and dust problem at Powder Coating plant..
F), The guidance of the countermeasure for the poor appearance caused by
the thinner for the paint diluted by the organic solvent.
G) The guidance and the analysis for the spray coating skill.
-----to visualize the level of the skill by Multi Display Compilation of
PC. which can clarify the delicate skill deference.
3. The existing equipment
A) Green Laser Sheet Light. ( Power;1000mW)
Green Laser Sheet Light is the high power visible and useful
equipment which can visualize the floating dust of over 10μin the atmosphere
of the coating area by the mechanism of Mie scattering and Tyndall scattering.
B) HID Light (Luminous Flux 3600 lumens.)
This equipment is the portable searching light used HID for visualizing
the floating dust. This equipment which uses Lithium Battery is
suitable for the visualizing of the dust which Laser can not show , at
the place of the setting zone after spraying booth and at inside of the
baking oven.
C) Particle sensor for rough particle
This particle sensor can record and measure the number of rough particle
of 5~50μｍ size which cause the coating dust and seeds.
Also we can visualize the dust distribution (where is bad circumstance)
at the whole coating area by taking the transition graph with the
combination of the Lithium polymer battery and Data logbook.
And we can clearly visualize the relation between the number of the dust
and the temperature and humidity which are measured at the same time by
making the graph.
D) Fog machine
This equipment will be applied the visualization of the air flow and can
visualize the air flow as like an Indian ink drawing by the combination
of Fog machine and Green Laser sheet light.
E) LED Light (Luminous Flux 400 lumens.)
As this equipment is the strong power portable LED Light, this can observe
the surface of the substrate before coating by shining them.
F) Digital Microscope (200 and 400 magnification)
They can be connected to PC.
G) Other equipments
We try to visualize the electrostatics phenomenon by checking the number
of the dust and seeding, as taking the popular equipment used at the home.
We disclose the supplier name and the detail information of all existing
equipments to the customers which we have contracted.
The customer will be able to became to observe the own circumstance of
the coating area by themselves, after the completion of our consulting
activities by learning our procedure.
4.1 The process of the consulting (Monthly visiting)
A) The consulting requested from the customers
We make up the visiting schedule after receiving the request of the
customers for the consulting activities by E-mail.
The fee of 1st visiting for the consultant activities is also charged.
We do not have the fee free system for the consultant activities.
B) Visiting
We clarify the following items at 1st visiting for the consulting.
a; the confirmation of requested products and subject.
b; the checking of the coating place.
c; the presentation of the equipments for the consulting.
d; the confirmation of the customer request, object, condition and schedule.
C) The signature of the contract.
D) The starting of the Consulting
a; We try to make the whole activities how we countermeasure
understand to the persons related the consulting by doing the lecture of
our procedure for dust and seeding problems at 1st visiting.
b; The confirmation of the transition of 1st run ratio.
c; The confirmation for the activities of the previous guidance.
d; The consulting for the countermeasure by verbally after checking the
coating place.
e; The confirmation of the contents and summary.
The summary for the consulting activities is described on the white board
as minutes.
We do not make the report document for the consulting.
f; The decision of next visiting date.
4.2 The process for the consulting activities of one time visiting.
We can do one time visiting consulting.
1st Day ; The lecture of our activities and the checking of the coating
place.
① We check the coating place at short time for taking the lecture which
is corresponded to the current situation.
② We do the lecture and explain the mechanism and the
countermeasure of the coating problem.
2nd Day; On the Morning
-The consulting at the coating place on the Morning
We go to the coating place with the persons related coating and observe
the real cause of the problem by taking many equipments which visualize
the problem phenomenon and find out the solved subject and problems.
We measure, evaluate and observe the current problem which happen at the
coating place with the persons related the coating.
On the Afternoon
-The actual doing of the improvement activities for the countermeasure.
We think over the priority order and the subject for the countermeasure,
under discussing the real cause and the actual problems.
We actually carry out the countermeasure which we can do immediately
under standing at the same thinking for the actual problem and the improved
items with the persons related the coating.
3rd Day On the Morning
We continue the improvement activities and make the presentation
documents for our activities.
On the Afternoon
The presentation for the improvement activities and the making of
the summary.
※ We can change to the regular consulting by the customers request
after the completion of one time consulting.
5. The expected outcome
Generally at initial stage, 1st run ratio will be started at 50~80%,
then it will become over 90% after 1 year consulting.
Finally 1st run ratio will become 95~98% after approximate next 1 year.
There are the customers which 1st run ratio is over 99% after the continuous
activities of 6 years.
Although even we do the best consulting, the improvement activities
should be done by the customers themselves finally.
We can not commit the target figure of 1st run ratio.
My role is to teach, support and consult.
The customers can not acquire good result without the actual
improvement activities.
6. The advantage of the introduction of the consulting activities.
A) To definitely get the consulted and checked point for the coating place
by the long experience which we have worked at the actual coating plant.
B) The responsibility persons for the coating job ,not the management, can be consulted directly the advice of the improvement point.
As the management persons may take the action for the appointed
result, they can judge everything from a broader point of view.
C) The speed for the improvement can be quick due to the reflection of
the experience and knowledge for the coating consultant.
D) The period of the education which achieve the professional level
for employee can be shorten by having the opportunity of the
professional education from the consultant.
E) The customer can organize the project which fits the own situation by looking at the actual coating place, not by teaching the reference book.
F) The customers can learn the procedure for own activities to the
difficulty jobs or the subject which they must do sometime by promoting
together with the consultant.
G) The customers can be advised everything which they do not understand
by the consultant like the home doctor at all time.
H) Since the consultant continue to get and analyze a lot of the coating technical information, customers can be taught the proper way and the right information which is referenced to the subject of each customer from among many coating and painting technical information.
I) The customers can make good use of the human network of
the consultant.
J) The customers can be taught where their technical situation are now
as compared the other competitors.
K) The customers can effectively promote the improvement and
development activities as followed the right way and procedure, not in
a haphazard way.
7. The actual result samples of our consulting activities in past.
H company: the coating technical guidance for Aluminum wheel for car.
(continue from June 2005 .)
N company: the guidance for the countermeasure of the coating
appearance problem for body.
(from June 2008 to August 2008 )
D company: the guidance for the countermeasure of the coating
appearance problem for body.
(from October 2007 to March 2008)
T Company; the guidance for the countermeasure of the coating
appearance problem for the automotive interior plastics
parts. ( irregularly from September 2008 )
S Company; the guidance for the countermeasure of the coating
appearance problem for the automotive plastics bumper.
(from June 2009 to August 2009)
K Company; the guidance for the countermeasure of the coating
appearance problem for frame of Personal Computer.
( irregularly from September 2009 )
T Company; the guidance for the countermeasure of the coating
appearance problem for the blade of the wiper at cars.
(continue from January 2006 )
M Company; the guidance for the countermeasure of the coating
appearance problem for the plastics cap of the cosmetic
container. (from February 2010 to August 2010)
W Company; the guidance for the countermeasure of the coating
appearance problem for the titanium frame of the glass.
(from March 2010 to December 2010)
F Company; the guidance for the countermeasure of the coating
appearance problem for the gas heater equipment for
the house. (continue from September 2009 )
H Company; the guidance for the countermeasure of the coating
appearance problem for the rear plastics doors at cars.
(continue from October 2010 )
F Company; the guidance for the countermeasure of the coating
appearance problem for the magnesium frame at camera.
(continue from September 2010 )
S Company; the guidance for the countermeasure of the coating
appearance problem for the button of the portable phone.
( January 2011)
Y Company; the guidance for the countermeasure of the dust and seeds
problems for one kind of film.
U Company; the guidance for the countermeasure of the dust and seeds
problems for the plastic name plate at cars.
8. The fee for the consultant.
200 thousand Yen per 1 day ( 5hours).
The guidance will be taught by Japanese.
When the translator will be needed, it should be prepared by customers.
The customers should pay the traffic fee from Japan to the local area and
the hotel fee.
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