The secret to any successful painting process begins with the cleaning process. The performance of powder coating is significantly influenced by its ability to adhere properly to the substrate material. Surface preparation is the most important factor affecting adhesion in the powder coating process. The presence of even small amounts of surface contaminants, oil, grease, oxides etc. can physically impair and reduce coating adhesion to the substrate.

Many fabricators struggle with the surface preparation of metal fabricated parts due to the lack of adhesion on the edge of parts processed through the laser. During the laser cutting process oxygen is used an assist gas during laser cutting of mild steel. The oxygen causes an exothermic reaction that creates heat, which helps the laser cut through the metal. The oxygen creates an oxidized edge that makes it difficult for powder coatings to adhere to the area exposed to the laser cutting.

To provide adequate cleaning A-1 Fabricators & Finishers provides a 5 stage cleaning process that removes this oxidation and allows for proper adhesion of the powder paint to the material. Listed below are the 5 stages and a brief description of each stages function.

Stage1: Acid – Descale or Laser Etch

1^st step of the process is the spray application of a liquid acidic compound used to remove laser edge oxides and heat scale.

• Removes Laser Edge Oxide
• Removes Heat scales

Stage2: Rinse

Product is then rinsed with a water spray to stop the acid cleaning process

Stage 3: Iron Phosphate – Cleaner/Coater

Parts are then sprayed with an acid cleaning concentrate that also applies an iron phosphate conversion coating. The coating provides an etching on the material that enhances paint adhesion.

• Provides etching enhancing adhesion

Stage 4: Rinse

Product is again water spray rinsed to stop the phosphate etching process.

Stage 5: Seal/Rinse

Final stage applies a sealer that is safe for all metals. Sealer application provides a rust inhibitor that prevents flash rust of materials.

• Safe for all metals
• Controls flash rust
• Improves salt spray and humidity test results

To assure proper adhesion is achieved in the cleaning process prepared samples are Cross Hatch Tested at a minimum of twice per shift. A crosshatch pattern is made though the film to the substrate. Detached flakes of coating are removed by brushing with a soft brush. Pressure-sensitive tape is applied over the crosshatch cut. Tape is smoothed into place by using a pencil eraser over the area of the incisions. Tape is removed by pulling it off rapidly back over itself as close to an angle of 180º. Adhesion is assessed on a 0 to 5 scale, reference ASTM D3359-09^E2 Test Method B for Cross Cut Tape Test Requirements. Click on link to review testing process. https://www.youtube.com/watch?v=EyzzUVjEGnU

A-1 Fabricators and Finishers recognized success of our Self-Directed Work and the residual benefits being realized.

Operating under a self-directed workforce allows for each employee to be responsible and accountable for their own productivity. This concept is practiced throughout all divisions of the company and basic guidelines have been established. Assuring that the company’s expectations are clearly understood the specifications of the guidelines have been documented in our employee handbook.

In this environment the diversity in personalities plays an important factor in the success. The many inherent traits of individuals to be leaders, followers, detail oriented, enthusiastic, etc., allows for diversity in our workforce. This diversity allows for the

strength and weakness of all individuals to be utilized and fosters an environment of individuality and importance. To learn more on understanding personality types this page has been found to be useful. http://www.hiresuccess.com/help/Understandingthe4PersonalityTypes.htm/ .

The concept of a self-directed workforce is achievable by empowering and trusting our employees in their decision making process. An often seen advantage is that employees openly communicate and resolve their concerns amongst each other. Continuous improvement efforts are consistently being implemented as individuals share their expertise and needs. Problem solving skills are realized with the promotion of expertise of the employee’s skills and knowledge. Individuals are respected for their contribution and have developed a sense of pride in the roles they perform.

Each employee is responsible for the quality of work produced. Guidelines in the form of Control Plans have been established with the input of employees performing the operations. Employees perform and document established inprocess inspections prior to moving product from their area. Inspection department performs sampling inspection and provides feedback to applicable employees in cases where standards have not been met. Providing real time feedback allows employees the opportunity for immediate corrective

and preventative actions to systems and processes.

Employee performance and productivity is monitored through our Enterprise Resource Planning System. ERP is business management software—typically a suite of integrated applications—that a company can use to collect, store, manage and interpret data from many business activities. Work is scheduled and released to manufacturing were employees are responsible for assuring that product is processed in the order of operation by due dates. Once an operation is completed employee then moves the job to the following operation as listed on the job work order and records the information into the ERP System. Through utilization of the ERP system full traceability of a part history, past or present, is captured recording employee identification, time, and materials.

Through implementation of self-direct work force the need of supervision throughout the manufacturing process has been eliminated. Employees have proven to perform at higher standards and the reduction in payroll is beneficial in reducing the Cost of Goods. Cost of Goods is the direct costs attributable to the production of the goods sold by a company. Through the reduction of cost allows labor rates to be reduced and savings are reflected in the pricing reductions experienced by our customers.

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Debbie Throenle
dthroenle@a1fab..biz

Ph (513) 724-0383 Ext 101
(513) 724-0387