Views: 0 Author: Site Editor Publish Time: 2026-07-08 Origin: Site
In early 2025, a major home appliance OEM approached DINGPRECISION with a challenge: their existing coating supplier was delivering batches with 12-18% visual reject rates — pinholes, orange peel, color variation, and dust contamination on white (RAL 9016) finishes. These defects required costly rework and created delivery delays.
The customer needed a partner who could deliver consistent, defect-free coating at scale.
Defect | Percentage | Root Cause |
Dust contamination / dirt inclusion | 6.2% | Poor booth air filtration |
Pinholes / outgassing | 4.5% | Inadequate pretreatment |
Orange peel (uneven surface) | 3.8% | Incorrect film thickness control |
Color variation (ΔE > 2.0) | 2.1% | Curing temperature inconsistency |
Poor edge coverage | 1.4% | Faraday cage effect / gun positioning |
Total reject rate | 18.0% |
Metric | Before | After | Improvement |
Visual reject rate | 18.0% | 0.08% | 99.6% reduction |
Film thickness (target 80-100 µm) | 60-130 µm | 82-98 µm (±8 µm) | 3x better consistency |
Color variation (ΔE) | 0.5-2.4 | 0.2-0.8 | All batches ≤1.0 |
Adhesion (ISO 2409) | Class 1-2 | Class 1 (100%) | Zero adhesion failures |
Customer inspection pass rate | 82% | 99.92% | Near-perfect |
The 0.08% reject rate has been sustained for 12 consecutive months across over 500,000 coated parts.
1. Root cause analysis works — Treat coating defects as process problems, not random occurrences.
2. Measurement is the first step to improvement — Without daily data, quality improvements are guesswork.
3. White coating is the ultimate test — If a supplier can deliver defect-free white finishes, they can handle any color.
4. Vertical integration enables control — DINGPRECISION could implement these changes because we own the entire coating line.
Need consistent, audit-grade powder coating for your OEM parts?
Request a Custom IP-Rated Enclosure Quote
Phone: +1 3142997740
Email: niewenhui@dingprecision.com
Website: www.dingprecision.com
