Coating is a specification most of the loss hides behind. A surface prepped below grade, a film thickness under spec, a holiday or a run — each sends the piece back for a second pass that costs a full coat of material and a full cycle of time. On pipe the same story is 3LPE and FBE rejects. The piece booked as coated; the re-coat did not.
Your ERP logs the pieces coated and the paint issued.
It won’t tell you a batch failed DFT and went back, or that the failures all trace to a prep grade that slipped.
Why the gap existsWhere the losses hide
A re-coat is one piece in the output and two coats in the material and time. It is invisible unless the failure and its cause are logged.
Coating adhesion is decided at blasting, to a grade like SA 2½. Prep that slips below it produces failures that show up two stages later at DFT, by which point the cause is gone.
Film thickness under spec, holidays and porosity each send a piece back for a re-coat. Tagged by cause they separate into prep, application and material; counted together they are one reject rate that points nowhere.
Every re-coat is a full coat of paint or coating material on a part already counted. Per-piece or per-square-metre consumption is the number that shows the loop, and it is the one nobody keeps.
The join
Same run, same clock, same asset — three streams that only mean something together.
Pieces coated, paint and coating material issued, jobs completed.
The DFT or holiday failure tagged by cause against the prep grade, and material consumption tied to the job and the catalogued item.
Coating reject rate read against prep grade, and material cost per piece read against the re-coat loop — so the failure traces back to blasting, not just to the paint booth.
What Munshi surfaces
Teal is normal, maroon is flagged. Illustrative data.
Two pieces came in under the specified film and went back. Both trace to a prep note.
Tagged by cause, so prep, application and material separate instead of averaging into one rate.
When an outcome moves and a signal moves with it, Munshi shows both and says they moved together. It does not tell you one caused the other. The operator confirms the cause, and the confirmed cause is written back to that asset’s register — so the pattern is already named the next time it appears.
Related stages
Delays and mismatches that never book as downtime.
NCRs and hydrotest fails that keep tracing to the same joint.
Get started
See this on your own line.
Bring a month you already understand. The useful test is whether Munshi finds what you already know — and then what you didn’t.