MAN Truck and Bus Paint shop Process
Table of Contents
Introduction 5
Paint Shop – historical background 6
2013 Reality check – A lesson in complacency 7
Key Improvement Areas 9
In Conclusion 11
References: 12
Appendix A 14
Appendix B 15
Appendix C 16
Introduction
The process of painting a bus body at MAN Bus & Coach has been selected as the subject of our investigation and discussion. The painting process is a crucial aspect to the overall quality finish and final delivery to the end customer. Since the paint is what the customer can touch and feel it is vitally important to see to it that the paint process upholds a very high standard. There are a number of formalised processes in place that see to it that quality is constantly being monitored and measured. There are seven major production phases in the manufacture of a bus body at MAN Bus & Coach, viz:
Structure
Panelling
Drop-on, i.e. marriage of body to pre-assembled chassis
Paint zone
Trim zone 1
Trim zone 2
Final Finish, sign off and delivery to customer
The performance objectives of the MAN Bus & Coach plant are that of quality and dependability; Quality above all else, Consistently. With volume demand at MAN Bus & Coach having doubled in 2013 from 1.25 units per day to 2.5, the paint process has been under severe pressure to deliver consistent quality with this increased volume throughput. The following discussion highlights the challenges that the management team of MAN Bus & Coach have faced to achieve the increased volume demand whilst maintaining the highest level of quality. Whilst the simplest solution would be to purchase a new and more modern paint shop facility, this is not possible due to the rigid budgetary constraints facing the company at present. Therefore other options have been investigated and the best solution implemented within these budgetary constraints.
Paint Shop – historical background
MAN Bus & Coach South Africa purchased the current painting facility back in 2007 from a MAN plant in
Introduction 5
Paint Shop – historical background 6
2013 Reality check – A lesson in complacency 7
Key Improvement Areas 9
In Conclusion 11
References: 12
Appendix A 14
Appendix B 15
Appendix C 16
Introduction
The process of painting a bus body at MAN Bus & Coach has been selected as the subject of our investigation and discussion. The painting process is a crucial aspect to the overall quality finish and final delivery to the end customer. Since the paint is what the customer can touch and feel it is vitally important to see to it that the paint process upholds a very high standard. There are a number of formalised processes in place that see to it that quality is constantly being monitored and measured. There are seven major production phases in the manufacture of a bus body at MAN Bus & Coach, viz:
Structure
Panelling
Drop-on, i.e. marriage of body to pre-assembled chassis
Paint zone
Trim zone 1
Trim zone 2
Final Finish, sign off and delivery to customer
The performance objectives of the MAN Bus & Coach plant are that of quality and dependability; Quality above all else, Consistently. With volume demand at MAN Bus & Coach having doubled in 2013 from 1.25 units per day to 2.5, the paint process has been under severe pressure to deliver consistent quality with this increased volume throughput. The following discussion highlights the challenges that the management team of MAN Bus & Coach have faced to achieve the increased volume demand whilst maintaining the highest level of quality. Whilst the simplest solution would be to purchase a new and more modern paint shop facility, this is not possible due to the rigid budgetary constraints facing the company at present. Therefore other options have been investigated and the best solution implemented within these budgetary constraints.
Paint Shop – historical background
MAN Bus & Coach South Africa purchased the current painting facility back in 2007 from a MAN plant in
References: Interviews with MAN Bus & Coach management: Corne Venter – Projects Manager, Industrial Engineer Ruben Kubayi – Paint Shop Foreman Neville Dukhia – Quality Assurance Officer. Final Finish Bongani Ndlovu – Paint Shop operator Telly Mokoena – Paint Shop operator Appendix A Appendix B