【Process Improvement and VE Proposals for Press Parts】Switching from Outsourced Plating to In-House Painting to Shorten Lead Time and Reduce Costs

When surface treatment for press parts is outsourced, lead time and costs may increase due to transportation, inspection, and waiting time between processes. Quality management burdens may also arise, such as scratches during transportation or rework when defects occur at the outsourced supplier.

PRESS CRAFT (THAILAND) CO., LTD. does not simply continue using the specified processing method. After reviewing the required product quality and operating environment, the company also makes VE proposals that reconsider the process itself.

This article introduces the approach to process improvement and the steps taken toward implementation, based on a case in which an outsourced plating process was changed to in-house Solvent Painting. By reducing transportation and inspection processes, the change contributed to shorter lead time, lower costs, and reduced quality risks.

Contents

• Lead Time and Quality Issues Caused by Outsourced Plating
• Reviewing Requirements and Proposing VE from Outsourced Plating to In-House Painting
• Shorter Lead Time and Lower Costs through Reduced Transportation and Inspection Processes
• Process Changes Implemented Step by Step with Repeated Quality Verification
• Frequently Asked Questions (FAQ)

Lead Time and Quality Issues Caused by Outsourced Plating

When surface treatment after press forming is outsourced to an external plating supplier, transportation between processes can extend lead time and increase the burden associated with logistics and progress management.

When plating of press parts is outsourced within Thailand, multiple processes are required, including inspection after press forming, transportation to the external supplier, plating, and incoming inspection. In addition, vibration during transportation or contact between parts can create a risk of surface scratches and dents.

If a defect occurs at the outsourced supplier, rework may be required, such as stripping the plating, returning the parts, and reprocessing them. Such rework can affect production plans and may cause delivery delays.

Reviewing Requirements and Proposing VE from Outsourced Plating to In-House Painting

To improve lead time and cost issues caused by outsourced plating, it is important not only to continue using the processing method specified on the drawing, but also to reconsider the required product performance and operating environment and review the process itself.

Based on customer product specifications and required quality, the company makes VE proposals to replace external plating with Solvent Painting performed inside its own factory.

Requirements such as appearance quality, heat resistance, corrosion resistance, and operating environment are reviewed, and the technical feasibility of switching to Solvent Painting is verified.

By utilizing the in-house Solvent Painting line, the company can consolidate the processes from press forming through surface treatment within its own factory while maintaining the required quality.

Shorter Lead Time and Lower Costs through Reduced Transportation and Inspection Processes

By changing from external plating to in-house painting, transportation and waiting time between processes can be reduced, helping to improve the efficiency of the overall production process.

For example, the following labor, costs, and risks associated with outsourced processing can be reduced:

• Transportation time to the external processing supplier
• Logistics arrangements such as trucks
• Inspections before and after outsourced processing
• Work-in-process inventory waiting between processes
• Risk of scratches and dents during transportation
• Management workload related to coordinating quality and delivery schedules with the outsourced supplier

In addition, managing the processes from press forming through painting in-house makes it easier to consolidate quality control within the company.

If a defect occurs, related departments such as press forming, painting, and inspection can work together to identify the cause, enabling faster response to the issue.

By consolidating these processes, the company can not only shorten production lead time but also reduce costs such as logistics expenses and outsourced processing costs.

Figure: Comparison between the conventional process and the process after the VE proposal

Process Changes Implemented Step by Step with Repeated Quality Verification

When changing drawing specifications or adopting a new processing method, it is necessary to thoroughly verify the impact on quality and durability. In particular, when changing a surface treatment process that has been used for many years, it is important to carefully confirm whether the required quality can be maintained, not only whether cost and delivery time can be improved.

In this case, technical discussions were held with the customer’s headquarters in Japan, painting samples were submitted, and verification tests were conducted repeatedly. Approximately one year was spent evaluating whether the new process could be introduced.

As a result, after confirming that the required quality could be achieved, the change from outsourced plating to in-house painting was adopted. This led to a reduction in outsourced processes, shorter lead time, and lower costs.

Similarly, there may be opportunities to review currently outsourced surface treatment or secondary processing depending on the product specifications and operating environment. The company reviews existing drawings and current processes and makes process improvement and VE proposals while taking quality, delivery, and cost into account.

※If you are considering reviewing your current processing flow, please contact us via the form below.

Frequently Asked Questions (FAQ)

Q1. Can you propose switching from plating to in-house painting for any type of product?
A1. It depends on the product’s operating environment and required performance. Conditions such as corrosion resistance, heat resistance, and appearance quality are reviewed in advance, and the company verifies whether Solvent Painting or Powder Coating can meet the required specifications before making a VE proposal.

Q2. If plating is specified on the drawing, can you also support the change procedure and technical verification?
A2. Yes. In addition to proposing an alternative process, the company supports verification toward mass-production application, including coating quality evaluation, prototype assessment, confirmation of processing conditions, and technical discussions with the customer’s headquarters in Japan or the customer’s engineering department.

Q3. How much can the lead time from press forming to Solvent Painting be shortened?
A3. Because transportation to external suppliers, incoming inspection, and waiting time between processes can be reduced, an overall reduction in production lead time can be expected. The specific number of days saved and the cost reduction effect are calculated individually after reviewing factors such as product shape, lot size, and the current process configuration.

※For further details, please refer to the materials or contact us via the form below.