Identify and rework paint faults on a curtainsider bulkhead

You are a vehicle painter in the paint shop.

Simulated workplaceIntermediate missionCAQA Nexus Automotive Manufacturing

What is going on

Curtainsider WO-26-0418 for Statewide Fleet Leasing failed the paint gate with two runs on the front bulkhead, recorded as NCR-26-089. The customer wants the vehicle on 9 October and it is one of three identical units that will be inspected during the customer quality audit. Booth 1 is being serviced because its airflow is dropping, so the rework must be done in booth 2. Last week a painter entered a booth during flash off without a respirator and reported chest tightness, so the supervisor is enforcing booth entry rules strictly. Your respirator fit test is current and the air supplied set is available.

Tony Falzon, Paint Shop Supervisor
Subject: Runs on the curtainsider bulkhead: rework in booth 2

The paint gate found two runs on the front bulkhead of WO-26-0418 and the customer wants it on 9 October. I want you to identify the cause, rework the faults to the Paint Shop Operations Procedure and get it back through the gate. Booth 1 is being serviced, so use booth 2 and record the airflow before you start. Your respirator fit test is current, so use the air supplied set. Record the fault, cause and rework on the work order and update the non-conformance record when you are done.

Your brief

Identify the paint fault type and its cause, plan and carry out the rework to the procedure in booth 2 with the correct respiratory protection and booth checks, inspect and record the result on the work order and update the non-conformance record for re-inspection at the paint gate.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the Paint Shop Operations and Isocyanate Safety Procedure and describe the booth airflow check, respirator and booth entry rules you will follow for this rework.
From the photographs and description supplied by your assessor, identify the fault type, list the probable causes of runs and state which cause you believe applies from the work order records.
Plan the rework: sanding grade and extent, masking, primer or sealer if required, mixing ratio and pot life, coats, flash off times and dry film thickness target.
Record the booth 2 airflow reading and the mixing record in the format the procedure requires, including product, time mixed and painter.
Using the dry film thickness readings supplied, inspect the reworked area against the specification and the approved colour sample and record the result on WO-26-0418.
Update NCR-26-089 in the Non-Conformance Register with the cause, the rework completed and the verification the gate inspector must perform.
Record the hazardous waste from the rework and explain how it is stored and disposed of under the Hazardous Chemicals and Environmental Policy, and log the unlabelled solvent drum you found beside the booth on an Incident and Hazard Report Form.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Booth and respiratory protection plan
Fault identification and cause analysis
Rework plan with mixing and film thickness records
Updated work order and non-conformance record
Waste record and hazard report

Printing this is a record of what you explored. It is not a certificate or a qualification.