Waste Reduction of Powder Color in Coating Process of Air Conditioner Parts

This action research aims to reduce waste of powder color in powder coating process of air conditioner parts in a case company. Six-sigma methodology together with contemporary quality improvement tools and techniques such as seven basic quality control tools were applied. More workpieces were arranged on hanging hooks to increase spraying areas. Spraying gun movement levels were reset to fit with the size of individual workpiece. Speed of spraying gun movement and air pressure rate of the spraying gun were tested for more suitable parameters. It was found that waste of powder color significantly decreased without negative effect of higher defect rate. Production volume increase due to shorter cycle time, too.