Applying powder coatings
URN: SEMMPF230
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
2020
Overview
| This standard identifies the competences you need to carry out material finishing operations by powder coating methods, in accordance with approved procedures. You will be expected to confirm with the authorised person, such as your immediate supervisor, that the equipment is ready for the powder coating operations to be performed and that all the required components/materials and consumables are available. You will be required to operate the powder coating equipment, in line with safe working practices and approved procedures, continuously monitoring the coating operations and where necessary, making minor adjustments or seeking help from the authorised person to make the required adjustments, in order to ensure that the work output is to the required quality. Meeting production targets will be an important issue and your production records must show consistent and satisfactory performance. Your responsibilities will require you to comply with organisational policy and procedures for the powder coating activities undertaken and to report any problems with the powder coating activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your actions and for the quality of the work that you carry out. Your underpinning knowledge will be sufficient to provide a sound basis for your work and will enable you to adopt an informed approach to applying powder coating procedures. You will have an understanding of the powder coating process and its application and will know about the equipment, materials and consumables in adequate depth to provide a sound background for carrying out the activities, recognising and reporting powder coating defects and ensuring the completed components are to the required specification. You will understand the safety precautions required when working with powder coating equipment and materials. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace, and towards the environment. |
Performance criteria
You must be able to:
| 1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines 2. follow work instructions and specifications to apply powder coatings 3. ensure the material surfaces to be treated are prepared for the finishing operations 4. check that the finishing equipment and treatment solutions are set up and maintained at satisfactory operating conditions and levels 5. carry out the treatment process following operating procedures and to meet the component specification 6. ensure that the treated workpiece achieves the required characteristics and meets the finishing specification 7. deal promptly and effectively with problems within your control and report those that cannot be solved 8. ensure that work records are completed, stored securely and available to others, as per organisational requirements 9. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements |
Knowledge and Understanding
You need to know and understand:
| 1. the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you 3. the hazards associated with the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. the importance of keeping the work area clean and tidy, including the use of 5S or similar techniques 6. how to obtain and interpret the production documentation required during the coating activity 7. the basic principles of the operation of powder coating equipment 8. the visual checks to be made on components prior to powder coating 9. the pre-treatments to be carried out on components prior to powder coating 10. the methods used to hold/secure components during the powder coating process 11. the importance of monitoring the equipment settings during the powder coating process 12. the types of adjustment that can be made to equipment settings to maintain component quality 13. how to identify powder coating process faults (including missed coating, blow holes, incorrect colour, excessive coating, rippling, contamination, poor adhesion, low and excessive coating) 14. the basic quality checks to be carried out on powder coated components 15. how to pack and store finished components to avoid damage 16. the importance of keeping the plant and equipment clean 17. the procedure for the safe disposal of waste materials 18. the importance of completing the production documentation throughout the powder coating process 19. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve 20. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Apply powder coatings, carrying out all of the following activities: 1. use the correct issue of process documentation (as specifications, job cards, quality control documentation) 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. confirm with the authorised person that the plant is ready for carrying out the powder coating operations 4. maintain sufficient quantities of process materials and components during the production cycle 5. seek any necessary instructions and training on the operation of the powder coating equipment 6. follow the defined operating procedures ensure that the plant settings are adjusted (either by yourself or the authorised person) to maintain the correct customer specification 7. leave the work area in a safe and clean condition 2. Apply powder coatings to one of the following substrates: 1. ferrous material 2. non-ferrous material 3. glass 4. composite material (such as MDF) 3. Apply powder coatings using one of the following types of equipment: 1. fluidised bed dipping system 2. automated powder coating unit 3. manual electrostatic powder spray gun 4. Use one of the following types of powder coating materials: 1. fluidised bed thermoplastic coating powder 2. electrostatic grade thermoplastic powder 3. fluidised bed thermosetting powder 4. electrostatic grade thermosetting powder 5. Carry out five of the following activities during the powder coating process: 1. segregate any defective components (pre and post coating) 2. carry out pre-treatments (de-greasing, pickling, phosphating, cleaning) 3. load components safely into plant 4. monitor process equipment settings (time, pressure and temperature) 5. safely make adjustments to equipment settings 6. change/maintain pre-treatment filters 7. masking 8. jigging 9. wiring 6. Identify all of the following types of defect in powder coated components: 1. missed coating 2. blow holes 3. excessive coating 4. rippling (orange peel) 5. low coating 6. contamination 7. incorrect colour 8. coating adhesion 7. Carry out, four of the following checks on powder coated products: 1. freedom from damage 2. freedom from contamination 3. surface quality/appearance 4. completeness of coating operations 5. film thickness 6. gloss level 7. colour uniformity 8. coating adhesion 8. Carry out three of the following coating completion activities: 1. check that the curing process has been completed before packing 2. place components in the specified container/area 3. store components in the correct quantities/weight 4. use the correct packaging to avoid damage 5. complete the production documentation 6. place all labels/production documentation in the specified location 7. clean the tools and equipment 9. Check powder coatings applied to components comply with one of the following quality standards: 1. military or aviation 2. current industry standards or codes of practice 3. international standards 4. company standards and requirements 5. customer standards and requirements |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
2023
Validity
Current
Status
Original
Originating Organisation
Semta
Original URN
MPF2.30
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; applying; coating; powder; manual; automated; fluidised