Retrotec USACE - Manual (Page 415)

Appendix L L15
7.0.9 Improve product quality by improved process control.
7.0.10 Improve repeatability/consistency by using statistical process control (SPC).
7.0.11 Improve safety by thinking about the safest way before starting.
7.0.12 Reduce pollution/hazardous waste by modifying the processes that cause it.
7.0.13 Reduce labor cost by optimizing labor use.
7.0.14 Optimize overtime by analyzing the causes and correcting them.
7.0.15 Simplify processes by eliminating unnecessary, non–value added steps.
7.0.16 Reduce the number of process steps by questioning and challenging their value.
7.0.17 Improve tooling/fi xtures/jigs to increase capacity use.
7.0.18 Improve working conditions to improve productivity by increasing building ventilation.
7.0.19 Reduce work hours/day or work days/week by working on the important things.
7.0.20 Improve process specifi cations/documentation to treat continuous improvement.
7.0.21 Reduce inspections without reducing quality, by eliminating unnecessary inspections.
7.0.22 Optimize inventory by optimizing procurement/logistics.
7.0.23 Improve tools to increase productivity and product quality.
7.0.24 Simplify inspections by eliminating unnecessary requirements.
7.0.25 Encapsulate process to reduce indoor air-contaminating emission.
7.0.26 Change the process by replacing materials with lower-contaminant emission materials
when possible.
7.0.27 Increase accuracy, timeliness, applicability, and usefulness of the inspection by optimiz-
ing the inspection processes.
7.1 Painting
7.1.1 Recycle water used to collect overspray paint by treating water with dissolved air fl ota-
tion and fi lter dewatering system to separate toxic solids.
7.1.2 Install heat recovery from paint process; 40–60% of heat input is vented through the
exhaust from painting process, while additional heat is lost as waste heat through the
walls. Heat recovery in paint process can thus be signifi cant. However, some of this
heat recovered from the stack is low-grade heat. If the problem of tar contamination
can be overcome, heat can be recovered from the stack. Heat can be recovered using
heat wheels or other such technologies.
7.1.3 Maintain optimal air temperature and relative humidity for faster drying and to elimi-
nate rework due to defects in the coating. These parameters depend upon the type of
paint process and paint used.
7.1.4 Install VFDs on exhaust and supply fans connected to the sensor installed on the
compressed air line to the paint gun. VFDs allows reduction of exhaust and supply air
into the paint booth when there is no paint spraying. Reducing the volume of air put
through the paint booth also limits the amount of energy to treat the supply and ex-
haust air.
7.1.5 Use infrared paint curing. Replace gas-fi red low-bake ovens with infrared ovens to
speed up the stoving process. Infrared process reduces energy consumption by reduc-
ing paint booth size and increases productivity by reducing stoving time.