Check grinding disc condition before starting.

Use 60 grit disks for grinding only.

Required PPE: Pants, safety glasses, hearing protection, face shield, dusk mask, steel capped boots, gloves, covered skin.

Start with door face down.

Grind welds off all corners.

Take off welds at each corner, keeping all welds smooth.

After grinding check for pin holes, send back to welding station if needed.

Use 60 grit sandpaper Sand all grinding marks, scratches, and welding splatter from inside of door.

If the inside of doors are clean no scratches or welding splatter do not sand

remove sticker from robot welder

if sticker is within the outlined area no cleanup is required

If the sticker is outside the outlined area clean any residue with wax n grease remover. DO NOT sand the sticker residue it will just smear it around trapping dust creating rework.

Flip door and begin work on other side.

Grind all outer welds.

Keep grinder as flat as possible to avoid digging "dents".

Follow natural shape of door.

Grind corners to flow smoothly.

Rub engineers ink (blue dye) onto grinding marks.

When sanding, the ink will reveal what areas are not flat and need sanding to remove ink.

Sand grinding marks first, make sure flat faces are flattened off and corners are rounded to match the surrounding areas use 60 grit sandpaper

Sand all outer faces, removing scratches.

Keep sander flat.

Deep scratches may need to use edge of sander.

Make sure you flatten it off afterwards

If not flattened out after using the edge of the sander it will show out after pc as a dent usually requiring rework

Inspect for defects scratches, grinding marks, pinholes, missed welds.

Put door in trolley ready for secondary QC

Hang doors ready for powder coating.

If they failed inspection, return to fabrication for re-work.

Use air gun, blow down all surfaces of door.  

once all doors are hung and blown down with air use blow torch and burn any fluff/dust from outer edges of all doors prior to hanging on conveyor for pc