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For Hands-On Training Tailored to Smaller Companies (paint shops with 2-10 people), click here.
Course Description / Who Should Attend / About the Instructor / Agenda
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This 3 ˝ day class is intended to teach painters, supervisors and paint facility managers how to get the painting job done using the least amount of coatings and solvents, without slowing down production. Results from previous classes have yielded direct coating and solvent savings averaging 18%, and reductions in rework due to runs, sags, orange peel, “tiger striping”, shadows, etc., by up to 40%.
Day #1: All participants take a 25-question quiz to determine their incoming level of knowledge. Participants are taught how to recognize poor painting techniques that lead to excessive overspray and paint defects. Up to six painters are video taped as they apply coatings to metal surfaces. The participants together with the instructor then critique the video and point out all of the techniques that can be improved upon. Moreover, any equipment or spray booth factors that lead to poor results are also video taped and discussed with the class.
For each painter we record coating usage, gun-target distance, fan width, atomizing air pressure and fluid flow rate.
Day #2: Rating of the appearance and quality of the finishes from the previous day. All participants are taught how to measure the uniformity of dry film thickness on the painted panels. The results are discussed with the class.
This is followed by a full day of classroom instruction during which the participants are taught over 30 techniques for improving painting efficiency and strategies for improving processes, facility equipment and maintenance. All of these contribute to lowering operational costs and pollution, and more importantly eliminate or dramatically reduce future paint reworks.
Day #3: Hands-on demonstrations in a spray booth, which include measuring pressure drops across the air atomizing hose, demonstrating compliance of HVLP spray guns, measuring air velocity and turbulence in spray booths, determining lighting conditions in spray booths, evaluating the compressor, air regulators and filters, and measuring coating viscosity and fluid (liquid paint) flow rates.
The painters in the class then repeat the work that they did on Day #1 and all measurements are again recorded.
Day #4: Evaluation of the quality of the finishes from the previous day and measuring the uniformity of dry film thicknesses. Participants are shown the improvements over the results from Day #1.
Classroom instruction on the ingredients of paints, coatings and solvents (thinners), and why these lead to air pollution and hazardous waste. Instruction on what VOC and HAP are, and how the EPA and state agencies regulate them in surface coatings. This is followed by an in-depth discussion on recordkeeping, actions that can lead to violations, who is responsible for paying fines and who can go to jail.
The training program concludes with participants taking the same 25-question quiz that they took on Day #1. After the results are computed they are shown how impressively their own results as well as those for the class improved as a result of the training.
Certificates are issued at the end of the class.
Painters, paint handlers including those who deal with hazardous waste and hazardous materials, paint supervisors, facility managers.
Environmental engineers who have responsibilities for compliance and pollution prevention (P2) from paint facilities will also benefit greatly from the program.
Class Size Maximum class size for the program will be 30 persons. We will provide actual hands-on training for a maximum of 6 painters, but the class agenda has been designed so that even those who do perform painting during the class will benefit equally. All participants will learn how to identify good and poor painting techniques.
Ron Joseph M.S. is Principal at Ron Joseph & Associates, Inc., a coating and environmental consulting
Each day the class will end by 3:30pm. If needed we can change these times to suit the painters. Starting times will be as follows:
It is vital that the paint supervisors as well as painters attend. Those participants who do not want to paint will be given other tasks to perform while painting is in progress.
Unless the participants prefer otherwise, lunch will be taken from 11:30am - 12:30pm (Occasionally, painters prefer 11:00 - 12:00)
Day #1 8:00 am - 9:00 Either in Class Room or in Spray Booth, whichever is more convenient.
9:00 - 12:00 noon In Spray Booth Comprehensive Quiz All participants will be asked to complete a multiple choice quiz covering technical and environmental topics. They will not be asked to identify themselves, but the scores will be logged on the computer so that we can determine the improvement in knowledge before and after training. The quiz can be completed while the six painters go through the coating process. Every one will be given time to complete the quiz.
Paint Application Six painters, comprising novices and veterans to coat one large and one small panel each. Each painter will coat one panel in the horizontal position and one in the vertical position. All painting, including gun setup will be video taped.
1:00 pm - 3:30 pm - In Class Room Interactive Video Quiz A new video has been compiled that shows good and poor painting practices that have previously been video taped. Twenty scenes have been selected which comprise painters applying coatings to both flat panels, aircraft and components. A multiple choice quiz will be handed to all participants who will be required to review the video tape and identify the faults exhibited in each clip. The instructor will then explain the correct answers. By the end of this exercise all participants will be thoroughly familiar identifying good and poor painting techniques.
Review Video of Six Painters After the participants have been shown what to look for in painting techniques, they will review the video of the six painters recorded during the morning session.
Day #2 7:30 am - 8:30 am - In Spray Booth Quality control of panels coated on Day #1. This will comprise appearance and dry film thickness
8:30 am - 3:30 pm - In Class Room
Getting Sufficient Compressed Air to the Spray Gun Pressure drops: Compressor to regulator on spray booth wall, air hose, fittings.
Day #3: 7:30 am - 12:00 noon - In Spray Booth Demonstrations in the spray booth of the following:
Paint Application Six painters from Day #1 coat one large and one small panel each. Each painter will coat one panel in the horizontal position and one in the vertical position, but we plan to make the exercise more challenging. All painting will be video taped.
2:00 pm - 3:00 pm In Class Room
Day #4 7:00 am - 8:00 am - In Spray Booth Quality control of panels coated on Day #3. This will comprise appearance and dry film thickness measurements.
8:00 am- 12:00 noon - In Class Room
Recordkeeping Who is responsible for keeping a painting facility in compliance. Legal issues concerning violations, fines, etc.
Final quiz Repetition of quiz taken on Day #1. The results will be scored and we will compare the level of knowledge between before and after training. Individual participants will not be identified. All sores will be calculated for the group.
Evaluation All participants will be asked to complete a course evaluation form which will be sent to the sponsor of the training program.
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© 2008 - Ron Joseph, Paint Consultant in Saratoga, California |
