Xie Pin Xiong
Summary:This article introduces the details of implementing ISO, 5S, EPR (Environmental Protection and Responsibility) management for powder production and quality control, as well as the necessity of environmental protection control, along with examples of production and quality control. The aim is to promote the healthy development of the industry.
Keywords:ISO-TS16949; 5S; EPR; Environmental Control; Incoming and Finished Product Inspection
1、Introduction
This emerging, environmentally friendly powder coating has been developed and used in China since 1965, with over 40 years of history. Its "Four E" properties – Efficiency, Energy Saving, Environmental Friendly, and Excellent Finishing – have led to rapid development. In 2010, sales reached 910,000 tons.
The number of powder coating companies has increased significantly. However, there are differences in production and quality control capabilities among these companies, particularly among small and medium-sized enterprises. This article will discuss the production practices and quality control characteristics of powder coatings, focusing on powder coating production and quality control.
2、Implementation of the ISO Management System
ISO (International Organization for Standardization) is a worldwide federation of national standards bodies, established to coordinate the efforts of these bodies.
ISO9000 series and ISO14000 series standards are a series of standards promulgated by ISO regarding quality and environmental management. They are widely accepted quality and environmental management system standards that can be adopted by companies to enhance quality management activities throughout the entire process, from procurement, design and development, production, inspection, sales, and use, and to strengthen "green and environmentally friendly" management activities. These standards are institutionalized and standardized, becoming the requirements and procedures for internal quality and environmental work within the company.
In the powder coating manufacturing industry, many small and medium-sized enterprises have already obtained ISO9001:2008 quality management system certification and ISO14001:2004 environmental management system certification. However, a significant portion of these certifications are merely for business development purposes, to meet customer demands, and are only implemented superficially without the comprehensive benefits of a fully implemented ISO management system. Such certifications lack practical value.
Of course, many small and medium-sized enterprises have also obtained ISO management system certification and comprehensively implemented ISO management.
For example: After implementing ISO management and internal operating standards, the company's business continued to develop, allowing it to establish specific customer groups in specialized fields such as aluminum materials, electrical appliances, and automotive parts. To further enhance the company's management, and in conjunction with obtaining certifications such as the European "QUALICOAT" aluminum material certification and the "Global Green Partner" certification for SONY electrical appliances, our company has developed a variety of specialized powder formulations for automotive parts. Therefore, we have upgraded the existing ISO management system to ISO/TS 16949:2009.
ISO/TS16949:2009 is "Quality Management System – Automotive Suppliers – Application of Specific Requirements to ISO 9001:2008", drafted jointly by the automotive industries of the US, France, Germany, and the UK. It is developed by the International Automotive Task Force (IATF), which includes the automotive associations of the five countries (ANFIA, AIAG, CCFA, FIEV, SMMT, and VDA). Since ISO/TS16949:2009 includes all the content of ISO 9001:2008, obtaining ISO/TS16949:2009 certification also signifies compliance with the ISO 9001:2008 standard.
ISO standards are a globally recognized conformity assessment system, serving as a mark that a company has achieved the requirements of a quality management system. The implementation of ISO standards is a prerequisite for companies to align their management practices with international standards.
3、Implementation of the 5S on-site management method
5S originated in Japan, encompassing Sort (SEIRI), Set in Order (SEITON), Shine (SEISO), Standardize (SEIKETSU), and Sustain (SHITSUKE), often referred to as the "Five S Principles" or "Five S Method." It involves effectively managing personnel, equipment, materials, and methods within a production environment. This is a unique management approach employed by Japanese businesses. The underlying principle is illustrated in the following diagram:
To meet the further development needs of their businesses, some companies have expanded on the original 5S system by adding Safety, resulting in "6S"; others have added Saving, resulting in "7S"; and some have added Habits, Service, and Persistence, resulting in "10S". However, all these variations ultimately stem from the "5S" system. For example, in the "Sort" stage, materials are sorted and recycled, and unnecessary waste is cleared, which inherently involves both saving and safety considerations. Specifically, disposing of waste cleaning solvents in safety corridors is a clear example of safety concerns that should be addressed.
5S is the foundation of on-site management, the prerequisite for comprehensive production management (TPM), and the first step in comprehensive quality management (TQM), as well as a guarantee for the effective implementation of ISO. The effects of implementing ISO, TQM, and TPM are hidden and long-term, and it may take time to see significant results. However, the effects of 5S management are immediately visible. If 5S management is introduced during the implementation of ISO, TQM, and TPM, significant results can be achieved in a short period. For example, by organizing samples, leftover materials, and maintaining order, immediate benefits can be realized in recent orders.
The details of management determine success or failure. Our labeling system is very clear, even the laboratory sample recovery is divided into five categories: "Non-recoverable," "Interior dark color sample recovery," "Interior light color sample recovery," "Exterior dark color sample recovery," and "Exterior light color sample recovery."
Implementing the 5S on-site management method is the foundation for the perfect integration of ISO and ERP.
4、Promotion of EPR (Extended Producer Responsibility)
ERP is an abbreviation for Enterprise Resource Planning, which refers to the comprehensive integration of all enterprise resources information based on information technology and modern management principles. This provides enterprises with a comprehensive and systematic management platform for decision-making, planning, control, and performance evaluation. ERP systems are not only software management tools, but also a management philosophy and a management culture, which form the operational model of modern enterprises.
Most of the content in ISO can be integrated into an ERP system. The ERP system not only provides a scientific and efficient platform for the ISO quality management system, but also effectively solidifies the results of ISO implementation, allowing companies to fully benefit from the convenience and efficiency of informationization. The combined application of the two can complement and enhance each other, resulting in amplified effectiveness.
In the initial stages of implementing EPR, existing ISO-certified procedures, work instructions, or records can be incorporated into the relevant constraints and controls to facilitate the implementation of EPR. based on the characteristics of powder enterprises, processes and activities such as inspection records, production formulas, cost and loss accounting, finished product and raw material inventory control can be integrated into the EPR system, and the output formats of various modules within EPR can be standardized to meet ISO requirements for quality records, forming an organic whole that permeates at different levels.
Our company currently uses software developed with its own specific features. When engineers review the "Production Formulation Sheet," they can access inventory and inspection results for raw materials through the company's ERP management platform, and they can also refer to production formulas for different batches in the formulation database. After verifying the batch numbers and proportions of standard production formulas, the system automatically generates the "Production Formulation Sheet," "Shipping List," "Material Input List," "Quality Control Sheet," and product labels, and prints them. Subsequently, warehouse managers can input the number of mixing cans required for each order and distribute the materials according to the "Shipping List" one can at a time to the production workshop. Engineers use the "Production Formulation Sheet" to adjust the color. After production is complete, the system automatically calculates the total material input, qualified products, unqualified products, loss rate, and pass rate based on the entered data. Managers can clearly understand the daily inventory and outflow of raw materials and finished products, the production status and quality of each order, and the production yield of each machine. This allows for comprehensive control of personnel, equipment, materials, methods, environment, and measurement.
ERP is an advanced information technology system that provides a comprehensive management tool for businesses. The implementation of ERP is the logical link that integrates ISO, 5S, and ERP systems.
5、Environmental Control
Environmental control is a comprehensive undertaking, and relying solely on a single company's efforts is insufficient. It is necessary to require our entire supply chain to participate in environmental management to ensure effective environmental protection.
Powder coatings are a type of chemical product, and achieving a truly "environmentally friendly" status is challenging. They can only meet a narrow definition of "environmentally friendly," meaning they comply with relevant environmental regulations for specific applications, such as RoHS, toy standards, and REACH regulations. It is important to note that some clients require standards that are higher than those set by the European Union.
RoHS (Restriction of Hazardous Substances) is a regulation issued by the European Union's Directive on the Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment, which restricts the use of lead, mercury, cadmium, hexavalent chromium, and the two bromine-containing compounds PBB (polybrominated biphenyl) and PBDE (polybrominated diphenyl ether) in powders used for decorative and insulating purposes in electrical and electronic equipment. The specific limits for hazardous substances are as follows:
Powder coatings specifically formulated for toys and infant products, with restrictions on the content of eight heavy metals, in accordance with the regulations specified in EN 71-3:1994. +A1:2000, the Toy Safety Standard – Part 3: Migration of certain elements. This standard is comparable to the US toy safety standard ASTM F963-07.
The following table specifies the limits for specific hazardous substances:
REACH (Concerning the Registration, Evaluation, Authorization and Restriction of Chemicals) refers to the new chemical regulations introduced by the European Chemicals Agency (ECHA), which outlines the requirements for the registration, evaluation, authorization, and restriction of chemicals. As of December 19, 2011, the latest number of SVHCs (Substances of Very High Concern) is 73. The European Chemicals Agency plans to officially publish the 7th batch of 13 SVHCs on its website, bringing the total number of SVHCs listed in the REACH regulation to 86.
SVHC list is shown in the table below:
Powder coating companies engaged in international trade must adhere to stricter environmental controls due to varying environmental regulations across different countries and regions. Failure to comply could result in significant financial liabilities that companies cannot afford.
From design, order placement, production, shipping, to quality management, relying solely on inspection is insufficient to guarantee products that meet quality standards. We must implement a "three-no" approach to environmental control: "no entry, no use, and no release," ensuring comprehensive management throughout the entire process.
First, "not entering" refers to controlling the entry of raw materials containing harmful substances during procurement, which is the key to managing the procurement of environmentally friendly materials. How can we conduct environmental testing of incoming materials? How can we ensure that the purchased raw materials meet environmental standards? Because, the instruments used for testing harmful substances, such as gas chromatography-mass spectrometry (GC-MS), liquid chromatography-mass spectrometry (LC-MS), inductively coupled plasma atomic emission spectrometry (ICP), and other spectroscopic instruments, are very expensive. Few powder coating companies purchase these instruments for incoming material testing. Therefore, a common approach is to send materials for periodic third-party testing, and the test results are considered valid within one year. However, even if the materials sent for testing pass, it does not guarantee that each batch of incoming materials meets the standards. The longer the sampling cycle, the greater the quality risk. Therefore, in addition to sending materials for external testing, we also sign a "Green Environmental Commitment" with upstream suppliers, ensuring that the raw materials meet environmental standards. Turning environmental control into a systematic project, if any source is found that sells materials containing harmful substances, they are fully responsible. This allows for effective control of environmental risks in powder coating factories.
Secondly, "not using" refers to the use of raw materials with restricted hazardous substance content that are not qualified in the production process. For example, our standard requires a lead content of less than 90ppm. If raw materials with a lead content of 700ppm are diluted to less than 90ppm, it is still incorrect to use this method. The rule states that materials that cannot be used cannot be used, nor can they be used after dilution. Furthermore, it is necessary to prevent cross-contamination during production. Non-environmentally friendly raw materials and products should not be stored in the same warehouse, non-environmentally friendly raw materials should not be measured in the same weighing room, non-environmentally friendly products should not be produced on the same production line, and non-environmentally friendly products should not be produced in the same workshop. This ensures complete isolation from non-environmentally friendly products.
"Not to be shipped" means that our products cannot be shipped if they do not meet environmental requirements, as determined by inspection. Since most companies regularly send their products for inspection by third-party organizations, if non-compliance with environmental requirements is discovered, the company must also trace whether the products were shipped to customers within a specific period. If products have been shipped, they must be recalled.
6、Inspection and Control
The daily inspection work for powder coatings must be documented with a fixed and reasonable procedure, as well as a control plan and potential failure mode and effects analysis (FMEA) document. The inspection and control process includes incoming inspection, in-process inspection, and shipment inspection. For periodic inspection items such as: harmful substance content, weather resistance, and resistance to neutral salt mist, third-party accredited laboratories can be selected for regular testing. Routine inspection items require relatively low investment in instrumentation and equipment, so ensuring consistent quality is essential.
During inspection, first collect the third-party certified laboratory reports, MSDS, and "Green and Environmental Commitment" documents signed by the supplier for each incoming material. Then, verify that the expiration dates of the incoming material's hazard substance inspection reports are valid, that the hazard substance limits comply with standards, and that the inspection units and material names in the reports match those on the incoming material packaging; and that there are no prohibited substances in the MSDS component table, and that the supplier has signed a "Green and Environmental Commitment" document, etc. The completeness and validity of these documents are essential for environmental control.
Regular inspection of raw materials can be divided into several categories, such as epoxy, polyester, hardener, filler, additives, and pigments, and then the regular inspection items can be implemented. The regular inspection items for additives and pigments are typically limited to visual inspection and sample machining to verify the results. The regular inspection items and methods for epoxy resins are as follows:
The following are the routine inspection items and methods for polyester resin:
The following table outlines the standard inspection items and methods for curing agents.
The following table lists the standard inspection items and methods for fillers.
Visual inspection of the appearance is the initial assessment of incoming materials; softening point and melt viscosity provide reference for storage stability and leveling properties; epoxy value, acid value, and hydroxyl value provide reference for designing the proportions of the formulation; oil absorption provides reference for leveling and gloss; sieve residue can be analyzed to determine the amount of sand impurities in the filler.
The main quality control processes for powder coating include checks before extrusion and checks before grinding. After each batch of material is prepared, samples must be taken for extrusion, pressing, and powder spraying. only after the regular inspection items pass, can the material be mass-produced. Similarly, before grinding each batch of product, samples must be taken from the extruded sheets for grinding and powder spraying. only after the regular inspection items pass can the material be mass-ground. Regular inspection checks are also conducted during the grinding process.
The standard inspection items and inspection methods for powder coatings are shown in the following table:
Managing color variations is complex and time-consuming, requiring color correction for each batch produced. Therefore, it is essential to establish a comprehensive color control system. Define standard color tolerance levels and implement a color difference evaluation method that combines visual comparison and instrument measurement.
Powder coatings are shipped immediately upon production, with key quality control checks including visual inspection for clumping, and verification of the gloss level of products that undergo physical fading. If shipped after the storage period, standard inspection items must pass, and the product can still be shipped.
7、Concluding Remarks
Powder coating companies can standardize and digitize production and quality control through the implementation of ISO 5S EPR, making the entire control process clear and transparent. Therefore, incoming and finished product inspection is easy, and the potential risks of producing environmentally friendly powder coatings can be minimized. The implementation of ISO is crucial in production and quality control, and the implementation of 5S site management is a bridge, and the implementation of ERP is a logical link that leads to the perfect integration of ISO/5S/ERP for production and quality control. It lays the foundation for the smooth production and continuous stable quality, and ensures the products can go to the international market.