Thai Tohken向洗浄テスト立会い■ テスト条件● 使用US洗浄

Thai Tohken向洗浄テスト立会い

■ テスト条件

● 使用US洗浄機：WS-600-28、WS-600-40
● 洗浄テスト構成：
粗洗浄（強アルカリS400T）揺動有 WS-600-28にて ⇒ 防錆すすぎ（C-9）WS-600-40にて
● 1バッチ処理数：12本（パンチング洗浄カゴ使用）
● 使用洗浄液：S400T（強アルカリ）希釈5％、加温60度
● 洗浄タクト：洗浄10分（WS-600-28）⇒ 防錆すすぎ5分（WS-600-40）

■ 客先の洗浄状況：

● ディーゼル燃料噴射インジェクター（150mm長×φ15、突起部φ20mm）の浸炭防止剤の除去
● 現在の洗浄工程：
バブリング洗浄（粗洗浄）液温60度⇒ワーカーよる内径残渣拭き取り⇒高圧スプレー⇒防錆剤浸漬
⇒エアーブロー（油溜り残渣の除去）⇒箱詰め
● 使用液（超音波洗浄機に持ち込む恐れのある液体）
・リスカット（RIS CUT SZ-82） 製造元 NSルブリカンツ株式会社・ダフニー スーパーコートNR 製造元 出光興産株式会社
・防炭材（品名：カーボンバスター２２１N or カーボンバスター141熱処理行程により使い分け） 製造元 パーカー熱処理工業
*バブリング槽では30ロットに1回の頻度で液を全て入れ替え。
⇒864本／ロット×30ロット＝25,920本ごと

● 工程

熱処理行程
↓
リスカット50%＋RO水50%（液温70℃で防炭材除去）
↓
ダフニー スーパーコートNR 100%にて水置換
↓
真空洗浄機にて油除去（洗浄液 クリーナーSH 出光興産）
↓
超音波洗浄で残留防炭材除去（希望）（現行作業は、作業者による磨き作業）
↓
最終防錆
↓
Packing

・超音波洗浄機導入によって、1ロット（864本）／時間で、18ロット／日処理＝生産量15,552本／日ターゲット。
*24時間稼動×360日／年
・バブリング⇒ワーク内径残渣拭き取り工程はそのまま残し、US洗浄はその後の工程で実施。
・予算はMAX500万THB≒1,500万円

● 改善要望内容：
現在約10名程のワーカーが共同作業で洗浄しているので、作業者工数を減らして人件費削減を図りたい。

■ 一次テスト結果と考察

全体的な清浄度、特に客先が最も懸念されているワーク突起部のネジ溝部の浸炭防止剤はかなり除去できている。
布で擦っても除去できない浸炭防止剤残渣のある部分は塗布後からかなり日数が経過して固着しているのが原因
と考えられる。まずは、客先に当方の見解を説明した上で、洗浄後ワークを判断をしていただく。

● 提案予定の洗浄装置構成

①粗洗浄⇒仕上げ洗浄⇒防錆すすぎ⇒乾燥 *すすぎ槽への汚れ持込を低減する為。
②粗洗浄⇒防錆すすぎ⇒乾燥（客先に排水設備が無い場合）

ผลลัพธ์ (อังกฤษ) 1:

Thai Tohken for cleaning test attendance

■ test conditions

-use US washing machine ：WS-600-28, WS-600-40
-cleaning test configuration:
coarse cleaning （ strongly alkaline S400T ） rocking motion with at WS-600-28 ⇒ rust at the rinse cycle c-（ 9 ） WS-600-40
-: 1 batch processing of 12 books (punching cleaning cart use)
-use washing liquid ：S400T strong alkaline diluted 5%, heating 60 °
-cleaning eye contact: wash 10 minutes （ WS-600-28 ） ⇒ Rust rinsing 5 minutes （ WS-600-40 ）

■ customer cleaning condition:

-Diesel fuel injectors （ 150 × 15 dia., 20 mm protrusion of φ ） of carburizing agent for removal
-current cleaning process:
bubbling cleaning (rough cleaning) liquid temperature 60 ° ⇒ bore residue by the worker wipes ⇒ high pressure spray ⇒ anti-rust agents soaked
⇒ airbrush (removal of residue oil reservoir) ⇒ boxed
-use fluid (liquids that could bring ultrasonic cleaning machine)
-リスカット （ RIS CUT SZ-82 ） former NS lubricant co., Ltd. and Daphne Super coat NR manufacturer Idemitsu Kosan Co., Ltd.
• Anti-Carbonation materials （ according to product name: カーボンバ star 221N or カーボンバ star 141 heat treatment process ） manufacturer Showa Denko k.k.
* in the bubbling tank 30 lots at 1 liquid are all reversed.
⇒ 864 / lot x 30 lot = 25,920 book per

-stage

heat stroke
↓
リスカット 50% + RO water 50% (carburizing material removal in liquid temperature 70 ° c)
↓
water replacement in the Daphne Super coat NR 100%
↓
oil removal by vacuum cleaning machine (washing liquid cleaner SH Idemitsu)
↓
In the ultrasonic cleaning residual carburizing material removal (I hope) （ scheduled work is polishing work by ）
↓
final rust
↓
Packing

-ultrasonic cleaning machine introduced by 1 lot (864 books), time, 18 lot and date processing = production quantity 15,552 book / day target.
* 24-hour operation x 360 days a year
-bubbling ⇒ work bore residue wiping process intact, US cleaning carried out at later stage.
-Budget MAX500 10,000 THB ≈ 15 million ¥

-requested improvements:
Currently about 10 workers are washed by collaborative work, so reducing worker effort, seeking to reduce labor costs.

■ primary test results and discussion

carburizing agent work projections overall cleanliness, especially customers most concerned about screw Groove is considerably removed.
Due to pretty days have passed from the application after the stuck portion of carburizing agent residue cannot be removed by rubbing with a cloth
and considered. At first, customers explained our views onCleaning after work to make judgment.

-Cleaning equipment configuration suggestions will

(1) coarse cleaning ⇒ finish cleaning ⇒ rust rinsing ⇒ dry * rinse to reduce dirt allowed to tank.
(2) coarse cleaning ⇒ rust rinsing → drying (if no drainage facilities to customers)

ผลลัพธ์ (อังกฤษ) 2:

Witnessed Thai Tohken toward cleaning test conditions ■ Test WS-600-28, WS-600-40: machine wash US use ● : ● cleaning test configuration and ⇒ proof at (strong alkali S400T) Yuradoyu WS-600-28 rough cleaning Rinse rust in (C-9) WS-600-40 ● 1 batch processing number: (punching wash basket used) 12 5% (strongly alkaline) diluted S400T, warm 60 degrees: ● use cleaning solution ● Cleaning tact: cleaning 5 minutes (WS-600-40) rinse (WS-600-28) ⇒ rust 10 minutes : cleaning situations ■ customer removal of carburizing inhibitor (150mm length × φ15, protrusions φ20mm) ● of diesel fuel injection injector ● cleaning process: The current bubbling cleaning by (rough cleaning) liquid temperature of 60 degrees ⇒ worker wiped inner diameter residue ⇒ high pressure spray ⇒ rust inhibitor dip ⇒ air blow ⇒ boxed (removal of the oil sump residue) ● working solution (ultrasonic cleaning machine liquid) is likely to bring to -Risukatto (RIS CUT SZ-82) manufacturer NS Lubricants Co., Daphne Super Court NR manufacturer Idemitsu Kosan Co., and properly used by the 141 heat treatment process carbon Buster 221N or carbon Buster): (Name, Bosumi-zai heat treatment industrial manufacturer Parker replacing all the liquid at a frequency of one every 30 lots in * bubbling tank. ⇒864 lines / Lot Lot × 30 = 25,920 lines per ● process heat treatment process ↓ (carburizing material removal at a liquid temperature of 70 ℃) 50% 50% + RO water Risukatto ↓ water displacement at 100% Daphne Super Court NR ↓ vacuum cleaning machine oil removal at (cleaning liquid cleaner SH Idemitsu Kosan) ↓ in ultrasonic cleaning residual carburizing material removal (desired) (polishing work by the operator the current work,) ↓ final rust ↓ Packing by Ultrasonic cleaning machine introduction, 1 Lot at (864 pcs) / hour, 15,552 lines / day target 18 Lot / day processing = production volume. * 360 days / year × 24 hours of operation and leaving the process wipe bubbling ⇒ work inside diameter residue, US cleaning carried out in a subsequent step. · ¥ 15 million MAX500 ten thousand THB ≒ budget requests for improvement ● Contents: worker of about 10 people since the current has been washed with collaborative work, want to work to reduce labor costs by reducing the man-hours workers. ■ discussion with the primary test results carburizing inhibitor of thread groove of work protrusions cleanliness, customer is the most concern in particular overall is can be removed fairly. Cause a portion of the carburizing inhibitor residues which can not be removed by rubbing with a cloth to be're fixed number of days has elapsed after application of fairly are considered. First of all, on which has been described the views of our customers in, and you may be asked by the judge the work after cleaning. ● cleaning device configuration of the proposed plan for reducing dirt bring to the rinse tank ⇒ dry * rinse ① rough cleaning ⇒ ⇒ finish cleaning rust. (If there is no drainage system to customer) ⇒ dry rinse ② rough cleaning rust ⇒

ผลลัพธ์ (อังกฤษ) 3:

The use of

● at Thai Tohken counter washing test on the test conditions

■ US washing machine: WS 600, constituted by WS 600 40
● rough cleaning (cleaning test T strong alkali S 400) has WS swing at 600 to rinse for rust prevention, C) WS at 600. Batch number 1: 40
● 12 in use (）
● punching cage cleaning: cleaning liquid S 400 T (alkali) dilution and heating cleaning: cleaning tact
● 60 degrees ten minutes WS 600 (28) is enshrined in 5 minutes, rinse cleaning rust conditions of perfect WS 600 (40 ）

■ customerDiesel fuel injection by the injector (length × 150 mm. Phi Phi projection 15, 20 mm) of carburization inhibitor removal
● now bubbling washing cleaning by wiping the inner diameter (washing) residue in high pressure spray antirust agent is immersed in liquid
⇒ air blow by workers of oil temperature (60. Degree. Residue removal is enshrined in reservoir using liquid packing
● HTS squirrel threatened to cut, ultrasonic cleaning machine, RIS CUT SZ 82) at the NS manufacturer Co., Ltd. all rights reserved NR Daphne super coating manufacturer, Idemitsu Kosan Co.And a carbonaceous material by use of carbon or carbon N Buster 221 Buster 141 solution heat treatment process) to replace all of the frequency of using heat treatment technology manufacturer Parker bubbling tank 30.
⇒ 864 pieces lot lot 30 × 25, oil removal process in heat treatment process at the following

● squirrel cut too at 50 percent RO water temperature at 70 ℃ in water displacement at each vacuum cleaning machine in the steel material, including the following removal of Daphne super coating NR 920 (100% in the cleaning liquid cleaner SH at Idemitsu Kosan, including the followingRemoval of residual carbon material for ultrasonic cleaning (hope) in the present work, including work at the final polish ↓ ↓. At the Packing rust prevention and the ultrasonic cleaning machine is introduced by an operator, a lot of time (in) a lot in 18 day = 15, production process 552 day at the target. Under the work 24 hours / day 360 years wiping or bubbling process to the inner diameter of the work process, the residue left after the US cleaning process. The MAX 500 million budget at about 1 million yen THB, requested by

● contentCurrently about ten workers are cleaning work, so as to reduce the number of workers to reduce labor costs.

■ primary test results and overall consideration too clean, carburization inhibitor of the screw groove of the work process of the most concern to the customer can be removed. In the cloth can not be removed by the carburization inhibitor from the residue after the coating is fixed as well as the days passed and the probable cause. First of all, the customer to our views onAfter washing to work. In order to reduce the dirt on the proposed plan to

● cleaning device is composed of

① rough cleaning to cleaning rust finish drying. Rinse rinse tank.
② rough cleaning rust to rinse dried without drainage (customer)