Summer internship at Volkswagen

100 %
0 %
Information about Summer internship at Volkswagen
Education

Published on March 13, 2014

Author: AISHVARYEAGARWAL

Source: slideshare.net

Description

B.Tech. summer internship project presentation (internship in Volkswagen)- "Structure improvement and performance study of BASF clear coat and comparative analysis with PPG Asian. "

PRESENTED BY:- AISHVARYE AGARWAL Final B.Tech Paint Technology H.B.T.I. KANPUR PRESENTATION ON INDUSTRIAL TRAINING AT VOLKSWAGEN INDIA PRIVATE LIMITED (21ST MAY -1ST JULY,2013) CHAKAN,PUNE(MAHARASHTRA) SUBMITTED TO: -Dr. -------- Assoc.Prof & Incharge Training and Placement Department of Oil and Paint Technology(HBTI) Project guide: ----- (Manager, Paint

ABOUT VOLKSWAGEN GROUP  German automobile manufacturer,founded in 1938.  Head quarters -Wolsburg ,Germany.  3rd largest automobile manufacturer in world.  Largest car maker in Europe  Products range- small cars, luxury class vehicles& trucks.  60 production plants across the world.  Marketing in 150+ countries.

LOCATIONS ACROSS THE GLOBE-60 PRODUCTION PLANTS

VOLKSWAGEN FAMILY SKODA FAMILY

AUDI FAMILY THE PORSCHE FAMILY THE LAMBORGHINI FAMILY

Volkswagen India •Headquarters in Pune, Maharashtra (India). • Inaugurated - March 31, 2009 • Investment of 3,800 Crores (580 million Euros) •22 models in the Indian market. • High level of vertical integration. • Represented by three brands in India: Volkswagen, Audi and Skoda.

Key figures VW India plant Pune:  Plot size 575 acres  Annual working days: 278 working days  Work organization: 2 Coupled shifts  Machinery operation: 960 min/day  Capacity: 31 vehicle /hour  Output: 500 vehicle /day  Annual production: 130,000 vehicle P.A  Labor time: 48 h/week

VW -CHAKAN PLANT(PUNE)

PLANT LAYOUT VW PLANT CC BUILDING PRESS SHOP BODY SHOP PAINT SHOP ASSEMBLY SHOP ADMIN. DEPARTMENT HR IT FINANCE, PURCHASE LOGISTICS ENVIRONMENT SAFETY AND SECURITY MANUFACTURING ENGG. DEPARTMENT PLANNING PROCESS ENGG. PRODUCTION ENGG. MAINTENANCE ENGG. QUALITY

WASHER PRE TREATMENT CED BAKING OVEN DRYING BAKING OVEN PRIMER SURFACER APPLICATIONCLEANING SANDINGSEALINGSOUND DAMPERS BAKING OVEN BASE COAT CLEANINGFLASH OFFCLEAR COAT INSPECTION REPAIR WAXING TO ASSEMBLY LINE BODY SHOP PAINT SHOP LAYOUT To spot repair

SURFACE PRETREATMENT Pretreatment means treatments given to the metal surface before painting.  It can be said that paint decides life of object and pretreatment decides life of paint. PURPOSE OF PRE-TREATMENT LINE:-  To remove all organic or inorganic contamination from the metal surface.  To deposit an inert film of inorganic material.  To ensure superior corrosion resistance properties.  Stimulate adhesion of the subsequent paint film(CED).

STEPS OF PRETREATMENT  Spray Degreasing  Dip Degreasing1  Dip Degreasing 2  Spray Water Rinsing  Activation  Phosphating  Spray Water rinsing  Dip Water rinsing  Passivation  Water Rinsing  Empty Rotation

DEGREASING  SPRAY DEGREASING  DIP DEGREASING 1  DIP DEGREASING 2 (RO-DIP SYSTEM) PARAMETERS Temperature 50-60 Ph 9.5-10.5 Total Alkali 40-140 Free Alkali 1-6 Spray pressure 0.7-1.5 bar Surfactant concentration 0.5-1.5gm/l Oil content max 3 gm/l

DIP DEGREASING Ro-DIP DEGREASING

ACTIVATION  MAIN PURPOSE : Creation of activated groups to provide increased no. of crystallization nuclei on the surface.  ACTIVATING MATERIALS: Aqueous dispersions of Titanium Orthophospate  PROCESS : Before the process of PT/CED  DEPENDENCY:  PH  Concentration of titanium salts  Temperature of dosing

PHOSPHATING  Increases adhesive qualities of paint layers  Improves the corrosion resistance  The Zn, Ni, Mn compounds and the phosphoric acid along with the ferrous ion (FeII) from the steel surface are the layer forming compounds. Following Reactions Take Place During Phosphating:- Pickling reaction Fe + 2H3PO4 → Fe(H2PO4)2 + H2(g) Coating formation 3Zn2+ + 2H2PO4 - + 4H2O → Zn3 (PO4)2•4H2O + 4H+(Hopeite) 2Zn2+ + Fe2+ + 2H2PO4 - + 4H2O → Zn2Fe(PO4)2•4H2O + 4H+ (Phosphophyllite) 2Mn2+ + Zn 2+ + 2H2PO4 - + 4H2O → Mn2Zn(PO4)2•4H2O + 4H+ (ZnMn-phosphate)

PASSIVATION  PURPOSE: To improve corrosion resistance of phosphate layer  CHEMICALS USED: Chrome (VI), Cr (III), or chrome-free solutions like zirconium-based solution  WORKING: pore size reduction by precipitation of insoluble compounds and removal of secondary phosphate crystals by the acidic solution of the passivating agent.  PARAMETERS • Zirconium concentration 50–150 ppm • Fluoride concentration 50–200 ppm • pH 3.5–5.0 • Conductivity (20◦C) <600 μS cm−1

CATHODIC ELECTRO DEPOSITION COATINGS Process in which the positively charged paints, are deposited at the cathode are normally called as cathodic electro deposition (CED) coatings ELECTROCHEMICAL REACTION INVOLVED 1.Electrolysis 3. Electrodeposition 2.Electrophoresis 4. Electro-endosmosis ADVANTAGES OF E.D COATING 1.Environmentally friendly 3. Difficult parts / Deep areas 2.Corrosion protection 4. Reduces discharge of paints

Paint material for CED coating:- Pigment: -TiO2 (Rutile) Extender: Bismuth hydroxide, barytes and china clay. Neutralizing agents: -Acetic acid, Formic acid, Citric acid, Emulsion: -Water based. Binder: Amino modified Epoxy-Polyester resins

ULTRA FILTRATION Ultra filtration is a process for separating suspended solids and substances in a certain defined molecular weight range by using a thin, semi-permeable. The substances which pass through the membrane are called "filtrate" or "permeate". ADVANTAGES OF ULTRA FILTRATION:- We can reduce the loss of E.D. material. We can reduce the dirt particle of E.D. coat. We can reduce the wetting problem of primer. Membrane layer construction

SEALER LINE Purpose of sealing vehicles:- To protect against: •Water leaks •Dust and fume intrusion •Corrosion •Chipping force

PRIMER SECTION STAGES OF PRIMER SECTION TAG-O-RAG WIPING ROBOT PRIMING STATION FLASH OFF ZONE DRYING ZONE ( PRIMER OVEN) PRIMER OVEN

PRIMER SANDING BOOTH CED MARK SLUDGE PHOSPHATE MARK OVER SPRAY SAGGING SEALER DAMAGE EXCESSIVE DIRT HAIR PRIMER DEFECTS

TOP COAT SECTION IT HAS FOLLOWING ZONES: - EMU ZONE MANUAL BASE COAT PAINTING BASE COAT PAINTING BY ROBOTS (IN 2 STAGES) FLASH OFF ZONE CLEAR COAT APPLICATION FLASH OFF ZONE DRYING OF TOP COAT (TOP COAT OVEN)

EMU ZONE Removes environmental loose dirt sanding dust

BASE COAT APPLICATION MANUALAPPLICATION:-on the interior surface of the body APPLICATION BY ROBOTS:- First stage :6 robots used ,we get 60 to 70% thickness Second stage 3 robots are used and in further we get 30 to 40% thickness. FLASH OFF ZONE:- At this section solvent is evaporated at room temp to make uniform layer of basecoat. CLEAR COAT APPLICATION MANUAL APPLICATION: - interior clear coat application is done by manual. EXTERIOR APPLICATION:- For external coating of the body 6 robots are used. They work on bell atomizer principle. They sense body and automatically started to apply clear coat

TOP COAT APPLICATION Movement axes of a painting robot. LCC in robo arm.

PROJECT Structure improvement and performance study of BASF clear coat and comparative analysis with APPG HIGHLIGHTS: •Define the problem and study of background •Quantification of defects •Actions undertaken for improvement. •Comparative Analysis of PPGA and BASF clear coats. •Conclusion

Background •Improper structure readings and crater issues with Candy White and Reflex Silver of existing clear coat. •BASF clear coat started on 14.05.2013 in UCW and on 15.05.2013in RS on trial basis for 1month. •Current colour-supplier details COLOUR BASE COAT CLEAR COAT CANDY WHITE APPG BASF REFLEX SILVER APPG BASF FLASH RED BASF BASF DEEP BLACK BASF BASF PEPPER GREY BASF BASF CAPPUCINO BIEGE BASF BASF SHADOW BLUE APPG APPG TERA BIEGE BASF BASF

Structure Theory The total appearance and the visibility of structures depend on the structure size, the observing distance and the image forming quality. Structure size Visibility of structures depend on -  structure size the observing distance the image forming quality. The waviness of automotive paints is in a range of approx. 0.1 to 30 mm wavelength. Short distance (shortwave) Large distance(longwave) Orange peel can be seen on high gloss surfaces as a wavy pattern of light and dark areas.

STRUCTURE PROPERTIES IN PAINT FILM •Long wave •Short wave •DOI Instruments used: Wave scanner (to measure LW, SW, DOI), DFT meter (in µm). Theory: For primer: •Long wave range: V(0-10mm),H(0-20mm) If Long wave is out of range improvement in primer is required. •If Short wave is out of rangeimprovement in ED is required. For top coat: •Long wave range: V(0-13mm),H(0-5mm) If LW is out of range  improvement in clear coat is required. •Short wave range: V(10-30mm),H(10-25mm) If SW is out of range  improvement in base coat and primer is needed.

MEASURING INSTRUMENTS USED •Wave Scan meter: • DFT meter: It is used to measure the LW ,SW and DOI values of the coating film by rolling the instrument on the coating surface. It is used to measure the dry film thickness of coating and individual thickness of various coating layers.

4 4.2 3.8 3.9 4.4 4.7 5.3 5.1 4.9 4.9 4.9 4.9 4.9 4.9 4.9 4.9 0 1 2 3 4 5 6 UCW Hz LW VW spec Sign off spec UCW POLO Hz LW TREND 10.8 11.6 11.2 8.6 10.1 9.1 9.6 9.7 0 2 4 6 8 10 12 14 UCW Vt LW VW spec Sign off UCW POLO Ver. LW TREND Structure trend of BASF clear coat on UCW

PERFORMANCE OF BASF CLEAR COAT AND IMPROVEMENT ACTIONS UNDERTAKEN Nature of change Problem description Before change After change 1 Change in process parameter- base coat. *(flow rate change) Visual structure not ok in A class area Flow rate BC1-100%,BC2- 100% Flow rate BC1- 90%,BC2-90% 2 Change in process parameter- base coat.*(robo-parameter optimization) Vento white tailgate not visually ok Brush no 28: FR,rpm,SA,hV 600/52/300/65 Brush no 29: 210/52/300/65 Brush no 28: FR,rpm,SA,HV 680/400/52/65 Brush no 29: 480/52/320/65 3 Change in processs parameter- primer.*(fine tuning of brushes) Sagging at various locations in grey primer- polo,vento,rapid Brush 5 6 7 10 Flow 280 500 500 450 Brush 5 6 7 10 Flow 240 450 480 400 16 35 5 180 180 350 16 35 5 140 140 300

MODIFICATIONS IN CLEAR COAT 1. Increase in the percentage of slow solvent from 0% to 1.7% 2. Additive addition in clear coat- 0.06% flow leveling additive added. 3. Viscosity reduction in clear coat: η=48sec(@27 ⁰C) to η=46.3sec(@27 ⁰C) and then to η=45.9sec(@27 ⁰C) by DIN4 cup. 4. Required change from Maintenance Dept.-flash off zone temperature reduced from 40 ⁰C to 30 ⁰C.

Comparison of characteristics of APPG and BASF Clear Coat Characteristics APPG clear coat BASF clear coat Spec. Actual Spec. Actual Supply viscosity at 23°C 45-75 61 sec >60 65 sec App. Viscosity at 23°C 48-52 51 sec 45-50 45 sec NVM% 45-54 49.28 45±2% 43.07 Elec. Resistivity 800- 1200kohm 849kohm 800±200 Kohm 810 kohm Thinner intake 10-30% 20% 6-10% 6% Gloss at 20°C 90-100 97 Min. 90 91 DFT 20-25 μ 35-45μ 38μ

Comparative analysis of BASF and APPG clear coat Plan of action: •Paint Vento candy white and reflex silver cars with BASF and APPG clear coat. •Check structure readings. 0 10 20 30 1 16 17 36 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Lw Comparison PPG clear coat … Specifications 0 10 20 30 40 50 1 16 17 36 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Sw Comparison PPG clear coat BASF clear Specification

Observations MODEL-COLOR BASF Clear coat APPG Clear coat Vento candy white LW 07/36 LW 00/36 SW 00/36 SW 00/36 Vento reflex silver LW 00/36 LW 00/36 SW 00/36 SW 00/36 Conclusion: 1.Vento candy white structure is better with PPG clear coat than BASF clear coat. 2. Vento reflex silver structure is at par with both clear coat

WASHER PRE TREATMENT CED BAKING OVEN DRYING BAKING OVEN PRIMER SURFACER APPLICATIONCLEANING SANDINGSEALINGSOUND DAMPERS BAKING OVEN BASE COAT CLEANINGFLASH OFFCLEAR COAT INSPECTION REPAIR WAXING TO ASSEMBLY LINE BODY SHOP PAINT SHOP LAYOUT To spot repair

WAXING WAXING : -Underbody parts PROTECTION : -To improve corrosion resistance, water, moisture resistance etc… Composition : -High quality paraffin : -Melting temperature – 120 ºC STAGES OF WAXING: - 1. Under body inspection 2. Pre-wax Preparation of body (Masking & Grommet Plug fix) 3. Wax System Preheat Oven Wax Flooding Station Waxed Body Tilting Station 4. Post wax body preparation (Wiping Of wax & Grommet Fix) 5. Under body preparation (Wiping Of wax & Grommet Fix) PARAMETERS: - Oven temperature: - 110-120 ºC Flooding station: -220 ºC Flooding time: - 5 sec Hot water temperature: -130 ºC Tilting: - 45 sec Cleaning: - solvent, medical cloth, manual operation

SALIENT FEATURES:  Latest technology: 1st installation of this kind of system in India  Best rust prevention in vehicles  100% automatic application AUTOMATIC HOT WAX FLOODING SYSTEM SIDE DOOR WAX FLOODING SYSTEM UNDER BODY WAX FLOODING SYSTEM

TYPES OF AUDIT PERFORMED AT PAINT SHOP CP 5A •Appearance properties- Gloss, thickness, color, Structure. •Mechanical properties- cross hatch test-(adhesion check),stone chip resistance test(by S.C.R gun 100 gm metal chips, 3bar pressure ,at the same spot) Corrosion audit •Checks for sealant defect i.e. missing of sealant in an area. •Checks for grommets and damper sheets defect. Wax audit •To check proper application of wax on car floor –near rocker panel area. Destruction audit •Check for at least one number of each model in a month by totally destroying it and analyzing unaccesible area by endoscope. FREQUENCY OF AUDITS 1% of total production, i.e. around 2 cars per shift goes to audit area

THANK YOU!

Add a comment

Related presentations

Related pages

Internship < Students < Come and join us - Volkswagen Personal

International Internships at Volkswagen, our special brochure on completing an internship abroad, contains all the information you need for each site, ...
Read more

Volkswagen Distinguished Scholars Program: Summer ...

The Volkswagen Distinguished Scholars Program offers paid summer internships for students from five select Tennessee universities allowing them the ...
Read more

Students < Come and join us < Volkswagen Personal

Students; University graduates; Experienced ... Internship; Final paper/dissertation; Internship. All you need to know about an internship at Volkswagen. More.
Read more

Students Experience Summer Internships at Volkswagen ...

Summer internships at Volkswagen Chattanooga allow students to apply their German language and culture knowledge while gaining valuable career experience.
Read more

Summer Internship with Volkswagen India Private Limited ...

Roshan Kadam from Symbiosis Institute of Operations Management shares his internship experience with Volkswagen India Private Limited, Pune
Read more

Volkswagen Undergraduate Internships - Oak Ridge Associated

The Volkswagen Distinguished Scholars program provides undergraduate science majors in Tennessee research internships at Oak Ridge National Laboratory.
Read more

VOLKSWAGEN GROUP OF AMERICA, INC.|Internship How to Apply ...

Find out VOLKSWAGEN GROUP OF AMERICA, INC. internship requirements, application process, deadline and contact information.
Read more

Summer Internship | Volkswagen

Summer Internship Would you like to complete an internship in the lar gest plant in the region? We give such a possibility - Volkswagen Poznan offers its ...
Read more

VW | Drive Your Career

Advanced job search. Save this Search. Beginning of the main content section. Results per page. ... © 2011 Volkswagen Group of America, Inc.
Read more

Internship > Students > Joining Audi > AUDI AG

An internship is the perfect way to start your career. Expand your theoretical knowledge through challenging practical experience, ...
Read more