PAINT ENGINEERING: PAINT SHOP

CONTAMINATION CONTROL
GUIDELINES

COPYRIGHT© 2000 GENERAL MOTORS CORPORATION

ALL RIGHTS RESERVED
 CONTENTS

ACKNOWLEDGEMENTS ..............................................................................................V
HOW TO USE THIS GUIDE......................................................................................... 1-1
CONTAMINATION GLOSSARY AND IDENTIFICATION LIBRARY................ 1-2
COMMON ICONS ............................................................................................. 1-2
COMMUNICATION TIPS .................................................................................. 1-2
TRAINING TIPS ................................................................................................ 1-2
TOOL TIPS ....................................................................................................... 1-2
APPENDICES ................................................................................................... 1-2

CHAPTER 1 - INTRODUCTION TO CONTAMINATION CONTROL .......................... 1-3

CONTAMINATION CONTROL PRACTICES.................................................... 1-4
ESSENTIAL ELEMENTS OF BEST PRACTICES - CONTAMINATION
REDUCTION IN PAINT OPERATIONS ............................................................ 1-4

CHAPTER 2 – CONTAMINATION DIAGNOSTICS..................................................... 2-1

ORGANIZATION............................................................................................... 2-1
SELECT AND DEDICATE CONTAMINATION CONTROL PERSONNEL ....... 2-1
ESTABLISHING A CONTAMINATION CONTROL TEAM ............................... 2-5
GM CONTAMINATION CONTROL TRAINING ................................................ 2-6
CONTAMINATION CONTROL PROGRAM TIMELINE .................................... 2-7
CONTAMINATION IDENTIFICATION METHODS............................................ 2-8
CONTAMINATION CONTROL PROBLEM IDENTIFICATION SUMMARY
CHART ............................................................................................................ 2-11
CONTAMINATION PROBLEM IDENTIFICATION PROCESS ....................... 2-12
CONTAMINATION CONTROL PROBLEM IDENTIFICATION PROCESS .... 2-26
TEAM PROBLEM IDENTIFICATION PROCESS FLOW CHART .................. 2-26

CHAPTER 3 – PLANT AREA CHECKLISTS .............................................................. 3-1

CHAPTER 4 – PROBLEM SOLVING FOR CONTAMINATION CONTROL ............... 4-1

PURPOSE OF THE PROBLEM SOLVING MODEL ......................................... 4-2
DEFINITION ...................................................................................................... 4-2
CHALLENGES.................................................................................................. 4-2
BENEFITS......................................................................................................... 4-3
STEPS OF THE CONTAMINATION CONTROL PROBLEM SOLVING
MODEL ............................................................................................................. 4-4
IMPLEMENTING THE CONTAMINATION CONTROL PROBLEM SOLVING
MODEL ............................................................................................................. 4-5
STEP 1: SELECT CONTAMINANT .................................................................. 4-5
STEP 2: CONTAIN CONTAMINANT ................................................................ 4-9
STEP 3: CORRECT CONTAMINANT............................................................. 4-10
STEP 4: PREVENT CONTAMINATION.......................................................... 4-16
CHAPTER 5 – CONTAMINATION CONTROL GUIDELINES, PROCEDURES, AND
BEST PRACTICES ...................................................................................................... 5-1
PAINT SHOP CONSTRUCTION AND DEEP CLEANING................................ 5-2
DEEP CLEAN CHECKLIST .............................................................................. 5-3
PAINT SHOP FACILITIES CONSTRUCTION .................................................. 5-3
CLEAN ROOM PRACTICES ............................................................................ 5-8
BASIC PHILOSOPHY....................................................................................... 5-8
PHYSICAL CLEAN ROOM ............................................................................... 5-9
BEST PRACTICES ........................................................................................... 5-9
INDIRECT MATERIALS TESTING AND APPROVAL.................................... 5-15
MATERIAL QUALITY CHECKS ..................................................................... 5-18
DIRECT MATERIALS ..................................................................................... 5-18
PAINT TESTING AND CLEANING................................................................. 5-18
PROCEDURE A - USING MANUAL GUN LINE DROPS ............................... 5-21
EQUIPMENT ................................................................................................... 5-27
SAMPLING PROCEDURE.............................................................................. 5-28
LABORATORY TEST SERIES REQUIREMENTS ......................................... 5-30
PROCESS CHECK ......................................................................................... 5-33
WELD BALLS ................................................................................................. 5-33
THE BASICS OF WELD BALL AND METAL CONTROL .............................. 5-33
PROCESS ....................................................................................................... 5-34
EQUIPMENT ................................................................................................... 5-37
MAINTENANCE .............................................................................................. 5-39

CHAPTER 6 – COMMUNICATING EFFECTIVELY WITHIN THE TEAM.................... 6-1

COMMUNICATION METHODS ........................................................................ 6-3
COMMUNICATION TIPS .................................................................................. 6-6
EFFECTIVE FEEDBACK .................................................................................. 6-7
EFFECTIVE COACHING SKILLS..................................................................... 6-8
EFFECTIVE LISTENING SKILLS ..................................................................... 6-8
EFFECTIVE ONE-ON-ONE .............................................................................. 6-9
COMMUNICATION ........................................................................................... 6-9
GATHERING INFORMATION........................................................................... 6-9
GIVING INSTRUCTIONS ................................................................................ 6-10
NON VERBAL COMMUNICATION................................................................. 6-10
EFFECTIVE PRESENTATION SKILLS .......................................................... 6-11
EFFECTIVE MEETINGS ................................................................................. 6-11
APPENDIX A - TROUBLESHOOTING........................................................................A-1
BODY SHOP .....................................................................................................A-2
PHOSPHATE ....................................................................................................A-3
ELPO.................................................................................................................A-4
ELPO OVEN......................................................................................................A-5
ELPO STRIP-OUT BANK .................................................................................A-6
ELPO SAND......................................................................................................A-7
SYSTEM VERIFICATION..................................................................................A-8
SEALER ............................................................................................................A-9
SOLVENT WIPE .............................................................................................A-10
SYSTEM VERIFICATION................................................................................A-11
BLOW VAC .....................................................................................................A-12
FEATHER DUSTER........................................................................................A-13
PRIMER OVEN ...............................................................................................A-16
PREP BOOTH MANUAL SANDING AREA....................................................A-17
SOLVENT WIPE .............................................................................................A-17
SYSTEM VERIFICATION................................................................................A-18
BLOW VACS...................................................................................................A-19
FEATHER DUSTER........................................................................................A-19
THREE STEP FINESSE..................................................................................A-22
REPAIR DECK................................................................................................A-23

APPENDIX B - PLANT ASSESSMENT...................................................................... B-1

PAINT SHOP CONTAMINATION CONTROL FOUR MAIN FOCUS AREAS . B-1
PEOPLE........................................................................................................... B-1
PROCESS ........................................................................................................ B-1
MATERIAL ....................................................................................................... B-1
FACILITIES ...................................................................................................... B-1
KEY ISSUES IN THE PEOPLE AREA............................................................. B-2
KEY ISSUES IN THE PROCESS AREA.......................................................... B-3
KEY ISSUES IN THE FACILITIES AREA: EXISTING PLANTS...................... B-4
KEY ISSUES IN THE FACILITIES AREA: NEW PAINT SHOPS .................... B-5

APPENDIX C - COMMON CONTAMINANTS ............................................................ C-1

PERSONAL PRODUCTS................................................................................. C-1
DIRECT MATERIALS ...................................................................................... C-4
FOOD ............................................................................................................... C-7
APPENDIX D - START-UP PROCEDURE AFTER EXTENDED SHUTDOWN.......... D-1
BODY SHOP WASHER/HIGHLIGHTER.......................................................... D-1
PREPHOSPHATE OPERATIONS ................................................................... D-1
PHOSPHATE ................................................................................................... D-2
ELPO................................................................................................................ D-2
SEALERS (BODY AND PAINT) ...................................................................... D-2
PREP BOOTHS AND FEATHER DUSTERS................................................... D-2
COMPRESSED AIR STARTUP PROCEDURES............................................. D-2
IONIZE BLOWOFF .......................................................................................... D-3
POWDER PRIMER SYSTEMS ........................................................................ D-3
PRIME, TOPCOAT, AND FINAL REPAIR SPRAY EQUIPMENT ................... D-3
SPRAY BOOTHS AND AIR SUPPLY HOUSES.............................................. D-3
OVENS............................................................................................................. D-4
ABATEMENT ................................................................................................... D-4
PAINT CIRCULATION GUIDELINES FOR EXTENDED SHUTDOWN ........... D-4
SPECIAL CONSIDERATIONS FOR BODY PREPARATION AFTER
EXTENDED SHUTDOWN................................................................................ D-5
OIL DRIPS ....................................................................................................... D-5
DIRT AND DEBRIS.......................................................................................... D-5
PLASTIC COVERS, HOSE, AND OTHER CONTAIMINATION ...................... D-6
SANDING OPERATIONS ................................................................................ D-6
RECOMMENDED VALIDATION OF EACH MAJOR PAINT PROCESS......... D-7
PHOSPHATE ................................................................................................... D-7
ELPO................................................................................................................ D-7
SEALER ........................................................................................................... D-7
PRIMER ........................................................................................................... D-8
TOPCOAT, FASCIA, AND IN-LINE REPAIR................................................... D-8
FINAL REPAIR ................................................................................................ D-8

APPENDIX E - SUPPLIER FORMS.............................................................................E-1

GENERAL MOTORS PAINT ENGINEERING...................................................E-2
INDIRECT MATERIALS APPROVAL PROCESS ............................................E-2
SUPPLIER INFORMATION ..............................................................................E-2
GENERAL MOTORS PAINT ENGINEERING INDIRECT MATERIALS
APPROVAL PROCESS SUPPLIER ACKNOWLEDGMENT............................E-8

APPENDIX F - GLOSSARY ........................................................................................ F-1

APPENDIX G - CONTAMINATION IDENTIFICATION LIBRARY .............................. G-1

 ACKNOWLEDGEMENTS

Like any other project, this was far from a solo effort. We would like to take this
opportunity to acknowledge everyone who took the time and interest in making this
publication a reality. To them we are indebted.

Peter Neishl Paint Engineering

Larry Medler Paint Engineering
John Duggan Paint Engineering
Lori Michaud Paint Engineering
Pat Schoening Paint Engineering
Ryan Odegaard GM Wentzville Assembly
Dave Snyder GM Ft Wayne
Butch Bailey GM Wilmington
Tim Chubb GM Bowling Green
John Tate GM Moraine
Pat Rhodes GM Pontiac East
Elva Zamora GM Ramos
Scott Warda GM Orion
Steve Wickham BASF
John Loipersbeck Caligo
Cecilia Bahjet The DeLorean Group
Leslie DeLorean The DeLorean Group
Angela Hamilton The DeLorean Group
Donita Simpson The DeLorean Group
Dr. Engel Herberts Dupont Herbers Performance Coating
Pam Dyon Inspec Technologies
Bill Mayhew Inspec Technologies
Clark Steigerwald MIS

We would also like to thank Dino Precopio at Butterworth, and Dean Weston at MPW
filtration whose efforts made this book visually interesting.

A special thanks goes out to John Nimphius for his dedication and eye for detail.

Finally Brian Cherry who added our (and his) unique style to the writing. Thanks to Brian
for adding new life to the project, when it was needed most.

The tedious, front line efforts for this book were put forth by Alex Peat, Dave Edwards
and Glenn Ryan. They stubbornly moved forward to make this a reality.
Paint Engineering
Paint Shop Contamination Control Guidelines Introduction

HOW TO USE THIS GUIDE

“The Dirt Book” is broken down into six comprehensive chapters and several
appendices. Each chapter is a road map to stress free, on-the-job resolution to
contamination problems. Your problem solving efforts will be supported with applicable
case studies, best practices, and specific problem solving work tools.

The chapters are organized by subject as follows:

Chapter 1
Introduction

Chapter 2
Contamination Diagnostics

Chapter 3
Plant Area Checklists

Chapter 4
Problem Solving for Contamination
Control

Chapter 5
Contamination Control Guidelines,
Procedures and Best Practices

Chapter 6
Communicating Effectively Within The
Team

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Paint Engineering
Paint Shop Contamination Control Guidelines Introduction

CONTAMINATION GLOSSARY AND IDENTIFICATION LIBRARY

Not everyone is going to be familiar with every aspect of the terminology used in
Contamination Control. With this in mind, the Appendices include a Contamination
Glossary (Appendix F) to help you understand unfamiliar terms. Also included is a
Contamination Identification Library (Appendix G). This pictorial library is a useful
tool for confirming or clarifying the identification of a contaminant.

COMMON ICONS

Several common icons are used throughout this guide:

Communication Tips describe best practices in

communicating with team members. Most communication
techniques are covered in training programs offered at
GMU. These Communication Tips are examples of
Communication Tips
methods and tools paint shop teams and their members
might use.

Note: Please refer to Chapter 6 for more detailed

information on effective communication.

Training Tips refer to specific GMU courses. Team

members can attend these courses to sharpen or build
specific skills.
Training Tips

Tool Tips identify tools necessary to perform a specific

activity. Tool Tips may include both required and
suggested equipment.
Tool Tips

Job Aids are documents that you can remove from this
guide and use on-the-job.

Job Aids
Appendices are used for organizing detailed information
that you may wish to reference in the future.

Appendices

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Paint Engineering
Paint Shop Contamination Control Guidelines Introduction

CHAPTER 1 - INTRODUCTION TO CONTAMINATION CONTROL

Welcome to the world of paint contaminants. This book will be your step by step guide
through the problem solving maze and will aid you in finding permanent solutions to
your contamination problems. This guide is intended as a reference and is a key part of
the GM Contamination Control Process.

A successful paint shop must achieve three coating attributes:

• Consistent durability — important to achieve for corrosion resistance, delimitation

resistance, and humidity moisture resistance
• Good appearance — measured by Distinction of Image (DOI), Gloss, and Orange
Peel
• Defect free paint film — an essential ingredient for maintaining customer acceptable
quality
• Contamination is an undesired foreign inclusion in the paint film caused by
disturbances in the paint process or operation
• This guide provides methods and tools for identifying and analyzing contamination
sources.
• Proven industry techniques for contamination reduction and contamination control
"best practices" are included.

The successful, dirt defeating paint shop is committed to continuous improvement in

contamination control. By focusing attention on activities, measurement, analysis,
team involvement, and skill development, the paint shop team can solve problems more
quickly and competitively than ever before. This guide details the tools necessary to
achieve that goal.

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Paint Engineering
Paint Shop Contamination Control Guidelines Introduction

CONTAMINATION CONTROL PRACTICES

BASIC PREMISE
Management must reinforce its commitment to contamination control and consistently
support quality objectives. Everyone is part of the team. From the person spraying the
cars to the Directors. All members of the team must be committed to:

• Paint shop contamination control activities, training, and solutions

• Ensuring that the paint shop is recognized as a special factory environment
• Keeping the paint shop's focus on achievement of consistent and non-varying
processes and operations
• Keeping all paint shop personnel involved and aware of how their actions affect the
final quality of the product

ESSENTIAL ELEMENTS OF BEST PRACTICES - CONTAMINATION REDUCTION IN

PAINT OPERATIONS

Operations are monitored to insure that:

• Operation methods and procedures are clearly posted, readily accessible, and
preferably written by operators and/or team leaders
• Operators have mechanisms to flag problems (e.g., team leader notification) and to
inform up-line groups of problems for quick correction
• Operators clearly understand equipment basics
• New operators have required training periods
• Operators can define problems and respond to quickly and effectively
• Support personnel respond to problems quickly and effectively
• Operators have a sense of ownership and involvement in paint processes
• Operators understand their operation(s) and how they relate to contaminants and
contamination control
• Operators check results of their work to ensure that the intended result is achieved
• Operators maintain their work areas and equipment

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Paint Engineering
Paint Shop Contamination Control Guidelines Introduction

General Guidelines

Contaminants can cause havoc to the sensitive paint room environment. As a result, the
paint area must be treated with an almost operating room level of care and cleanliness.
To this end, a number of guidelines have been created to maintain the integrity of this
fragile environment.

• The paint shop must be segregated from other areas

• Access to the paint shop must be limited
• Anyone entering the paint shop must be properly dressed in Paint Engineering
approved paint shop coveralls and headgear*
• No wheeled vehicles are allowed in the paint shop (unless confined to paint)
• An active contamination and crater-causing agent awareness program is in place
• No food, drink, cigarettes, newspapers, or other fiber-generating materials are
allowed in the paint shop. The break room is exempt from this rule
• No lubricants containing silicone are allowed in the paint shop
• Only GM approved indirect material may be used in the paint shop
• If there is doubt to the crater causing potential of silicone, or any other material, paint
a test panel

Maintenance Guidelines

• Maintenance supervision and personnel clearly understand the basics of the

contamination control process
• Maintenance supports operators quickly and effectively
• Maintenance and Maintenance support adhere to all paint shop guidelines
• Repair areas are enclosed and located away from the product

Cleaning Guidelines

• Detailed operation sheets are provided (preferably written and approved by team
leaders/operators and management)
• Cleaning personnel must comply with paint shop guidelines
• Cleaning supports paint operations
• Cleaning supervision and personnel clearly understand the basics of the
contamination control process
• Personnel responsible for filter maintenance and replacement are provided
necessary training
• Storage areas are segregated from the process and are kept clean and orderly

These rules may seem stringent, even oppressive, but it is far easier to follow these
guidelines than to have a part come back for reprocess.

*You will need to refer to the GM approved indirect materials list.

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Paint Shop Contamination Control Guidelines Introduction

Reprocess

If a defect from a previous operation (e.g., Elpo defect sanding, sealer clean-up, moist
sanding) cannot be removed by normal finesse operation, it must be sent for
reprocessing. Below are main points to consider for in-process repair:

• When work is sent to reprocessing, more topcoat defects may be created

• The work force should be motivated to pay special attention to detail

The best solution to a problem is prevention. The goal of contamination control must be
to prevent defects before they reach the reprocessing stations by:

• Setting up operations so that no defect is passed on to the next area

• Identifying causes through problem solving and statistics
• Teaching operators to recognize defect causes
• Establishing a response system to allow feedback from operators
• The ultimate paint shop has very few in-process repair operations
• The performance measures of a paint shop are the amount of reprocessing and
amount of defect removal required
SUMMARY

An ounce of prevention saves everyone involved both time and trouble. Permanent
change and improvement can only be effective if the solutions become part of the
corporate culture. This guide is provided to help make contamination control a common,
continually executed process within the paint shop.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

CHAPTER 2 – CONTAMINATION DIAGNOSTICS

How do you find a defect? Once it has been found, do you know what you’re looking at?
And what do you do with it once it has been identified? This chapter will give you the
methods to solve the contamination madness. Diagnostic techniques for detecting,
identifying, and recording contamination will be covered in this section. To build skills in
specific areas, contact the appropriate training coordinator or the GMU web site for
GMU course descriptions and registration.

ORGANIZATION

SELECT AND DEDICATE CONTAMINATION CONTROL PERSONNEL

Any quality initiative is doomed without a dedicated team. A qualified staff of hourly and
salaried personnel will be necessary to implement a successful and continuous
contamination control program. These “Dirt Busters” will be responsible for:

• Achieving a sufficient skill level to identify contamination accurately and effectively

• Providing a sufficient flow of continuous data to statistically define causes
• Allowing historical tracking of the statistical data
• Communicating information to the paint staff
• Communicating effectively to that paint staff that the process used to achieve
absolute contamination control is just part of the greater whole of an ongoing
program to forever lock dirt and contamination out of paint shop

Dirt is a persistent foe and can’t be given a moment’s peace. To keep the contaminant
at bay, there must be an analyst assigned to each shift. All members of the
contamination control team in the paint shop should support the contamination analyst.

Selecting a Contamination Analyst

A good analyst is a rather meticulous and detail oriented individual who never tires of
asking the question, “Why?” These traits are not common. Education and seniority have
very little to do with what makes a good analyst. Therefore, he or she should be
selected very carefully. For this vital role, look to one of your hourly operators or
process engineers. Dedication to contamination control activities and a strong personal
dislike for defects should be other qualifying traits.

Most plants run more than one shift; therefore, you will need a minimum of one
contamination analyst per shift.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

To maintain the integrity and consistency of the contamination control process, analysts
must be protected from job rotations. These highly motivated individuals will be
responsible for training others in contamination control procedures.

Because nobody can commit everything to memory, the analyst will have to establish a
“Dirt” Defect Handbook. The analyst monitors each process (via contamination count
and identification) through critical analysis of the information. This “Dirt Detective”
identifies the source of contamination throughout the process.

Effective data collection and communication does not happen by accident. Every day
the analyst impacts the overall effectiveness of the contamination control process.
Through aggressive research, effective communications, leadership, and commitment
to a team environment, the analyst can affect change and accurately gauge
improvement.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

The table below lists the basic and advanced skills required of the typical contamination
analyst:

Required Skills of the Contamination Analyst

Job Skills Basic Advanced
Able to use 60X hand held microscope X
Able to identify paint defects X
Able to expose defects using diagonal cut X
Able to expose defects using horizontal cut X
Able to mount samples on microscope slides X
Able to use stereo microscope X
Able to use stereo microscope with camera X
Able to photograph defects successfully X
Able to compile and use reference library X
Minimum 1000 hours contamination analysis experience X
Knowledge of SOPs for facility cleaning X
Understands team’s role in contamination reduction X
Understands concept of continuous improvement X
Knowledge of methods and materials used in plant X
Understands paint theory and terminology basics X
Understands procedure for daily walk-through X
Understands function and role of contamination committee X
Understands complete paint process X
Understands paint department process flow X
Understands plant production and reject reports X
Understands method of calculating daily audits % X
Knowledge of computer basics X
Able to identify contamination and fiber defects X
Understands the use of Statistical Process Control X
Able to use Excel spread sheet program X
Able to use graphics program X
Understands the use of Pareto charts X
Able to use Microsoft Word (word processing) program X
Able to prepare daily reports to management X
Able to prepare weekly reports to contamination committee X
Understands the requirements for Ready-to-Paint jobs X
Understands process flow of entire plant X
Able to use cause and effect (fishbone) chart X
Able to make contamination reduction recommendations X
Able to prepare special reports to team X
Understands booth and system air balance basic X
Understands electrocoat paint application basics X

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

Required Skills of the Contamination Analyst

Job Skills Basic Advanced
Minimum 2000 hours contamination analysis experience X
Achieve measurable contamination reduction results X
Able to perform fiber ID using polarized light X
Have access to advanced analytical techniques such as
scanning electron microscope
Able to set up and conduct meetings X
Able to give presentations X
Able to perform root cause analysis X
Able to compile plant wide conformance parameter report X
Able to troubleshoot contamination problems at plant X
Understands use of 5 phase problem solving X
Understands concept of lean manufacturing X
Understands concept of quality gates X

The analyst is required to attain these job skills within a reasonable amount of time, (we
suggest within the first year). When going through the analyst selection process,
remember that your candidate may already have these skills in his or her tool kit or may
acquire them through on the job experience.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

ESTABLISHING A CONTAMINATION CONTROL TEAM

A team leader isn’t much good without being surrounded by a solid group. A truly
effective contamination analyst must have a group of qualified and dedicated
contamination-hating teammates. This indispensable team works with the analyst to
support problem-solving activities and to spread awareness to all operating groups
involved in the paint process. By identifying contaminant causes and creating solutions,
this team establishes a common and effective approach to implementing solutions.

A Contamination Control Team operates in the following manner:

• Becomes an integral part of problem solving and root cause identification

• Members of the team are from all disciplines as dictated by the local organizational
structure
• Has structure and function similar to a project committee
• Must be given authority to change things based on submitted data and facts
• Major improvements are submitted as regular projects with accompanying support
data
• Records are kept to track changes and their results.

Like most new things to an organization, there will be a degree of confusion and
misunderstanding associated with this initiative. A secondary objective of the team is to
create a common understanding of the process.

For long term success and the elimination of defects, the process must continue to get
better over time. To this end, the team must be focused on and support all continuous
improvement activities.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

GM CONTAMINATION CONTROL TRAINING

A well-educated team member is going to be a more effective team member. The GM

Contamination Control Training Program will educate team members and give them the
skills and strategies to analyze and eliminate defect-causing paint shop problems.
Contamination control training is an on-going process which must be reinforced daily.

Individuals are trained in the following areas:

• Contaminant identification and removal

• Statistical Process Control (SPC) methods for monitoring contaminant levels
• Facility and process investigative techniques
• Facilities maintenance relating to contaminant sources (oven/booth cleaning, filter
changes, etc.)
• Problem solving techniques (Cause and Effect Charts, Paint Systems Analysis
Checklist, etc.)
• Incoming material check procedure

Training Tips

• See page 2-22 for a list of suggested courses.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

CONTAMINATION CONTROL PROGRAM TIMELINE

(STARTING A NEW PROGRAM)
W EEK
AC TIV ITY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 24 +
IN IT IAT E P R O G R AM (3.1)
• Introduc tory Meeting
S E LE C T & D E D IC AT E P E R S O N N E L (3.2)
• D irt Analyst & D ata Tracking
• D evelop C ontam ination C ontrol Team
T R AIN & P R O VID E C O N T AM IN AT IO N C O N T R O L S K ILL S (3.3)
• D irt Analyst Training
T ools:
• "C ontam ination C ontrol G uidelines " M anual
• PD P C ours e
• C ontam ination C ontrol N etwork
• G M O nLine / "The Lates t D irt"
• Proc es s Know ledge
• Ins pec tion Standard
• Start SPC C harts
IM P R O VE & D E VE LO P S K ILLS (3.4)
• C redibility Support & As s is t Struc ture
• Start C ontam ination R eference Library
Tools:
• 60X Shop M ic ros c opes with Illum inators (6.10)
• Stereo Lab M ic ros c ope & Acc es s ories (6.10)
• Im age R ecording, Storage Sy s tem (6.10, Appen. F)
• Paint Test Panels /Paint Spray Fac ilities (6.2)
• Las er Particle C ounter (O ptional) (6.3)
• W ork w ith Team to Build Plant Involvem ent
C O N T IN U O U S IM P R O VE M E N T - 1 (3.5)
• Sequentially Selective Us e of Statistic s
• Preventive Methods (3.7)
Tools:
• C om pres s ed Air Test Kit (6.6)
• C om pres sed Air O il Indicator Tester (6.6)
• C om pres s ed Air M oisture Analys is Kit (6.6)
• Air Filter M em brane Tes t Kit, C lean Bench (6.7)
• H VAC Sm ok e Tes ter, Laser Partic le C ounter (6.8)
• Liquid Paint Tes t Kit (6.5)
C O N T IN U O U S IM P R O VE M E N T - 2 (3.6)
• C ustom er-O riented Feedbac k ( IC E, IUVA, R ailhead)
• Use Feedbac k to Im prove
• Adjus t Q uality Standard
D ISC R ETE EVENTS C O NTINUO US EVENTS

The training of an analyst and the formation of a Contamination Control Team is only
the beginning of improving and developing problem solving. Credibility must be
established if the program is going to gain any sort of momentum.

The culture begins to change as the data from the first analysis begins to surface. Little
if any credibility exists for operational changes indicated by the initial data. In addition,
analysts require intermittent visits by more experienced analysts and instructors. A one-
year learning curve will exist until initial analysts are fully confident and have attained
sufficient data and experience to be fully functional. At this time, communication within
the Contamination Team is also established.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

CONTAMINATION IDENTIFICATION METHODS

No machine or program has proven to be a good substitute for keen human

observation. Therefore, IDENTIFICATION depends heavily on the operators’
observation and expertise. Typically, operator IDENTIFICATION is performed after
Elpo, primer, and topcoat application. For the most part, operators on-line depend on
visual observation and touch with gloved hand.

Visual
An inspection method where defects are visually detected.

Glove
A method where defects are detected by feel or touch using a thin glove.

SLICING INTO DEFECT

Once a defect is discovered, the next logical step is to determine the identity of the
defect. To do this, the operator examines it through 60X power shop microscope.
Unfortunately, the accuracy of this method in identifying a defect is not absolute. To
investigate further, conduct this exam: cut the paint to expose the defect and observe
and analyze it through the microscope. This method is 90% accurate for identification
when used by a trained, experienced analyst.

There are two methods for cutting samples from a part:

• Diagonal cut
• Horizontal cut

Diagonal Cut (slicing)

Starting 1 to 2 mm to the left of the defect, the operator (using a No.11 scalpel blade)
cuts a wedge in the paint film down to the substrate. Cutting at a 30° angle, this
continues until the defect is exposed. Slices are saved on a microscope slide for
comparison to the photographic catalogue in the contamination library. This method is
recommended on scrap parts only because repair of the cut is usually not possible.
REMOVE

clearcoat
basecoat
primer
adhesion promoter

substrate

Revised: 10/12/00 Page 2-8

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

Horizontal Cut

Using a No. 15 scalpel blade, begin a horizontal cut 1 to 2 mm to the left and cut down
and up under the defect. Hold the scalpel blade parallel to the surface of the part. Parts
with samples cut in this manner can be reworked and in some cases finessed. A
representative selection of samples is saved on microscope slides for photographic
cataloguing in the contamination library. This is the primary method for contamination
identification

REMOVE

clearcoat
basecoat
primer
adhesion promoter

substate

Observation tools may also include the use of scientific instruments such as:

Shop microscope
Stereoscope microscope

Revised: 10/12/00 Page 2-9

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

Tool Tips
Shop Scope

This tool allows for “on the line” microscopic analysis and identification. However, it
does not allow for non-routine identification of the contaminant.

• 30x portable pocket microscope

• 60x modified measuring microscope with a small flashlight for illumination
• Scalpels, slides, tweezers

Tool Tips
Stereoscope

This tool allows for more detailed analysis and/or fiber comparison.

• Zoom microscope suitable for contaminant analysis

• Fiber optic illuminator
• Possible anti vibration stand
• Scalpels and tweezers

The stereoscope slides with photo attachments allow for fast and easy photography.
A TV display can be used for recording, team demonstrations, display, and possible
training tapes.

Tool Tips
Polarizing Microscope

This tool allows for identification of fibers.

• The highest level in contaminant analysis

• A true analytical method for fiber identification
• Requires extensive training and experience to use effectively

Revised: 10/12/00 Page 2-10

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

CONTAMINATION PROBLEM IDENTIFICATION PROCESS

Use of Statistics in Contamination Control

Very few problems are successfully or permanently solved by accident. Good planning
is essential to the elimination of defects. Effective strategies start with good information.
Statistical Process Control (SPC) is an invaluable tool to the creation of a well thought
out contamination reduction plan. The method of improvement outlined in this guide
includes an organized process for determining special causes at a specific location. The
importance, or rank, of causes is established through Pareto charts, which provide
statistical measurements. The team then focuses on the "significant few" causes
identified, uses problem solving techniques (see Chapter 4) to determine the root
causes, and takes action to eliminate them. Data gathered and charted by the analyst is
used to monitor the conditions and make improvements in the system.

CONTAMINATION CONTROL PROBLEM IDENTIFICATION SUMMARY

CHART

1. CONTAMINATE IS THE
5. EVALUATE
PROBLEM

SPC
U- CHART

4. IMPLEMENT
SOURCES CONTAMINATE
ID

2. ANALYZE
PARETO

3. PLAN

Revised: 10/12/00 Page 2-11

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

CONTAMINATION PROBLEM IDENTIFICATION PROCESS

SPC and Pareto charts provide the backbone of information for decision making. The
analyst uses a tracking system to determine the "significant few" causes of defects. In
this system, the analyst will:

1. Identify the high contaminant panel for the product.

2. Create a U-chart to record the contaminant level of the product prior to finesse under
current conditions as a basis to track future improvements.

3. Analyze the final product generated by the paint process. Identify contaminants by
layer, type, and sub-type. Generate Pareto charts for each category to focus their
problem solving efforts. Use U-charts to record the effect of problem solving and
process stabilization.

4. Conduct a special analysis of Elpo and primer layers to remove the masking effect of
in-process repair such as sanding of Elpo and primer. For example, a pre-finesse
analysis may pinpoint sanding dust as a problem. A root cause, as an example,
might emerge as follows.

Revised: 10/12/00 Page 2-12

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

Apparent Problem Underlying Cause

Too much sanding dust Too much sanding

Too many phosphate system impurities Weld balls primary impurity

in Elpo

Not removed by phosphate cleaning Trapped inside of product

stages

Phosphating system not designed to Not a problem with original product

remove design

New product has extensive MIG welding Welding methods are different

Appendix [A]
Related Materials
Appendices include the following related materials:
• Contamination identification process study (step by step)

Revised: 10/12/00 Page 2-13

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

IDENTIFY HIGH CONTAMINANT PANEL

Inspect contaminant defects by panel

Select minimum of 20 units in random blocks of 4 prior to finesse
• Make Pareto chart of defects per panel
Update Pareto Chart quarterly based on summary of data taken during last
quarter (New chart each quarter)

Pareto Chart - Dirt Defects Per Panel

50 48.2% Hood

45
40
35
% 30
25.8% R. Door
25
20
15
10.2% L. Door
10
6.8% L. Quarter
5.7% L. Roof
5 3.3% R. Quarter

0
1 2 3 4 5 6
Panel

• Identify panel with majority of defects/rejects (hood for example)

If during the update process a different panel is identified as the "highest defect
panel," the special cause should be identified but data should continue to be
taken on the original chosen panel.
Existing inspection practices may already be providing this data on a continuous
basis. This data may be used if sound.

Revised: 10/12/00 Page 2-14

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

EVALUATE PAINT CONTAMINATION (BEFORE FINESSE)

• Count particles on 5 groups of 4 panels per shift

• Make U-chart of average number of particles per chosen panel (hood) per shift

U-Chart - Average Number of Particles Per Panel (Hood)

5 UCL
5.04
4.5
4
3.5 U
# of 3.48
3
Particles
2.5
2 LCL
1.98
1.5
1
.5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Shift

Revised: 10/12/00 Page 2-15

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

ANALYZE PROCESS BY CONTAMINANTS IN EACH LAYER

(BEFORE FINESSE)

RECORD DATA BY PAINT LAYER

• Make Pareto chart of defects per paint layer

Pareto Chart - Defects Per Paint Layer

60
56% Basecoat

50

40

% 30

20
16.2% Prime

13% Charcoal

10
9.7% Elpo
5.1% Phospate

0
1 2 3 4 5
Paint Layer

• Identify layer with highest contamination defects

Revised: 10/12/00 Page 2-16

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

ANALYZE PROCESS BY CONTAMINANTS IN EACH LAYER

(BEFORE FINESSE)

• Make U-chart of average number of particles per paint layer per shift

U-Chart - Average Number of Particles Per Panel (Hood)

5 UCL
5.04
4.5
4
3.5 U
# of 3.48
3
Particles
2.5
2 LCL
1.98
1.5
1
.5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Shift

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

ANALYZE PROCESS BY CONTAMINANTS IN EACH LAYER

(BEFORE FINESSE)

RECORD HIGH CONTAMINANT IN PAINT LAYER

• Make Pareto chart of type of contaminants in paint layer

Pareto Chart - Type of Contaminants in Paint Layer

(Basecoat)

50 48.2% Fibers

45
40
35
% 30
25.8% Overspray
25
20
15
10.2% Paint Chip
10
6.8% Iron Filling
5.7% Peanut Shell
5 3.3% Hair

0
1 2 3 4 5 6
Type of Contaminant

• Identify contaminant with highest number of contamination defects

Revised: 10/12/00 Page 2-18

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

ANALYZE PROCESS BY CONTAMINANTS IN EACH LAYER

(BEFORE FINESSE)

• Make U-chart of average number of particles per paint layer per shift

U-Chart - Average Number of Particles (Fibers) Per Paint

Layer (Basecoat)
UCL
1.2
1.25

1
U
0.86
0.8

# of
0.6
Particles
LCL
0.4 0.47

0.2

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Shift

Revised: 10/12/00 Page 2-19

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

ANALYZE PROCESS BY CONTAMINANTS IN EACH LAYER

(BEFORE FINESSE)

RECORD HIGH CONTAMINANT SUB-TYPE

• Make Pareto chart of type of contaminant characteristics (i.e., type of fiber)

Pareto Chart - Type of Contaminants in Paint Layer

(Basecoat)

50 48.2% Fibers

45
40
35
% 30
25.8% Overspray
25
20
15
10.2% Paint Chip
10
6.8% Iron Filling
5.7% Peanut Shell
5 3.3% Hair

0
1 2 3 4 5 6
Type of Contaminant

• Identify contaminant characteristic with highest frequency of contamination defects

Revised: 10/12/00 Page 2-20

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

REPEATING THE PROCESS

As any paint shop staff member knows, dirt just has a way of sneaking in. To effectively
combat this ongoing problem, consistency within the process is a vital key to success. A
key element in the continuous improvement cycle is the necessity to repeat the process,
followed by monitoring changes and using analysis to help solve problems. Each time a
contamination analyst goes through the process of collecting data, he or she will see
changes occurring, even if only in small increments. This repetitive process includes
conducting the analysis, making and acting upon the charts, then going back and doing
SPC to get to the source of the defect. By repeating this process, the analyst will be
able to eventually identify the root causes of the contamination and eliminate them
permanently.

Measuring Results

Everything has a price. Improvements to eliminate dirt from the paint shop are no
exception to this rule. But how much is it going to cost? To justify improvements, the
analyst must measure the actual costs of average panel reprocess or, if applicable, an
average paint spot reprocess against improvements and long term reduction in
reprocess rates and total reprocess cost reduction.

To calculate an accurate reprocess cost, you should include all elements such as direct
labor, paint material, indirect labor (associated with reprocessing facilities and support),
the cost of energy to operate reprocess facilities, the cost of consumable materials,
associated cleaning costs, maintenance parts, and depreciation. As you can see, the
long-term cost of constant reprocessing can become rather burdensome.

Good practices can reduce reprocessing. Over time you will be able to statistically prove
significant savings. In other words, the value received from this effort can then be
quantified. In addition, cost reductions can then be calculated and an estimated value
can be assigned to future improvements. It’s basic economics. The less money you
spend on fixing mistakes, the more money will be available for improvements. Values
can be assigned to the reduced reprocessing efforts for historical and continuing
improvement purposes.

Revised: 10/12/00 Page 2-21

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

Training Tips
SPC and Control Planning Courses

For more information and skills consider taking these courses:

COURSE NO. COURSE TITLE

282 Statistical Process Control Fundamentals
2027 SPC Module (Paint Development Program)
13315 Process Control Planning forPaint (Paint Development Program)

Tool Tips
Pareto Charts
Pareto Charts are used to:
• Identify types of defects
• Identify frequency of defects
• Identify top 5 defects

Tool Tips
U-Charts
U-Charts are used to:
• Track defects
• Compare defects to control limits
• Identify average number of defects over time

Revised: 10/12/00 Page 2-22

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

Tool Tips
I-Charts
I-Charts are used to:
• Identify trends
• Reduce variation
• Problem solve
• Visually manage processes

Communication Tips

Possible methods of communicating a serious defect are:

• Verbal – communicate to the Contamination Control Team, supervisor, etc.

• Written reports/notices (in some plants)
• Discrepancy report
• Activating line-stop alarm
• Discuss the concern at the Contamination Control Team meeting

Revised: 10/12/00 Page 2-23

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

QUALITY GATES (AUDITS)

Variants are bad. It is a simple statement, but true just the same. So within our fight to
stamp out dirt, how do we control these variants? Well, to this end we have a “Quality
Gate.” This is an alarm to signal discrepancies. A Quality Gate guides the organization
to making better decisions by collecting and understanding variation data. By the simple
use of a control chart, the variant data allows all elements of the system to be observed
and followed. A reading of variation outside the control limits must be investigated and
identified.

The Quality Gate is a physical location(s) within the plant established by the Quality
Department where quality checks are performed and discrepancies are recorded and
displayed. The Quality Gate Process is an outgrowth of the Variation Reduction effort
designed to deal with discrepancy counts (items that would cause customer
dissatisfaction). These counts become the solid basis for sound decision making,
anchored in sound statistical theory.

Quality Gates occur at major points within the assembly process. They include:

Paint Shop Quality Gate

Inspection is performed at the end of the finesse line.

Global Corporate Quality Gate (End-of-the-line audit)

Final inspection occurs before the product leaves the plant.

Paint Engineering supports buy-off standards within the Global Corporate Audit and
requires that all plants support this same philosophy. Paint Engineering personnel
working as a team will incorporate the Quality Network Model and the GCA standards.
This ensures that continuous process improvement is in force and the tools to
determine customer requirements are in line with those GM applies to its product. At the
end of the day, the number of nonconformities is totaled and plotted on a control chart.

Revised: 10/12/00 Page 2-24

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

CONTAMINATION CONTROL METHODS — SUMMARY

Below is a summary of various contamination control methods you can use throughout
your dealings in and around the paint shop.

Method Purpose Usage

DETECTING/IDENTIFYING
Visual • Detection of contaminant with • Line-operator
the naked eye
Glove • Detection of contaminant by • Line operator
(touch) feel/touch
Shop Scope • Identify contaminant • Contamination analyst
• Contamination team leader
Stereoscope • Identify contaminant at a higher • Contamination analyst
level of magnification and depth • Contamination team leader
of field
Polarizing • Identify fiber contaminants at a • Contamination analyst
Microscope higher level of magnification • Contamination team leader
and depth of field
PROBLEM IDENTIFICATION
Pareto Chart • Summarize types of defects • Contamination analyst
• Summarize frequency of • Contamination team leader
defects • Process engineer
• Identify top 5 defects
U-Chart • Track defects • Contamination analyst
• Compare defects to control • Contamination team leader
limits • Process engineer
• Identify average number of
defects over time
I-Chart • Identify trends • Contamination analyst
• Reduce variation • Contamination team leader
• Problem solve • Process engineer
• Visually manage processes
QUALITY GATES
Method Purpose Time of Occurrence
Paint Shop • Continuous improvement • End of finesse
• Record discrepancies
Global • Continuous improvement • Before product leaves the
Corporate • Record discrepancies plant

Revised: 10/12/00 Page 2-25

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 2 – Contamination Diagnostics

CONTAMINATION CONTROL PROBLEM IDENTIFICATION PROCESS

The following is an example of using Pareto and U-charts for tracking the progress of
defect elimination. It does not represent a "textbook" on SPC techniques; rather it is a
suggested outline of procedures for a comprehensive statistical tracking system.

There are no examples of Special Study charts, but the same procedure for generating
and using Pareto and U-charts should be followed.

TEAM PROBLEM IDENTIFICATION PROCESS FLOW CHART

Construct “Layer Pareto”

1 from check sheets

Upon verification of corrective Select layer for contamination

8 actions, continue with next problem 2 team to address

Construct a “contamination
Implement corrective actions Repeat steps 1
7 to resolve the concern determine next area 3 Type by Layer” Pareto for layer
under investigation
of resolution effort

Construct a control chart for For layer selected, construct

6 each type of contamination
under investigation
4 a control chart to monitor
contamination level

Select type of contamination

5 for resolution

Problem solving for Steps 7 and 8 using the 5-phase approach will be discussed in
Chapter 4.

Revised: 10/12/00 Page 2-26

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 3 - Plant Area Checklists

CHAPTER 3 – PLANT AREA CHECKLISTS

We use them when we go to the store or on vacation, so why shouldn’t checklists be
used on the paint shop floor? With the use of a simple Cause and Effect Diagram, we
can find the source of a variation.

Most of the factors that will have an impact on paint contamination can be readily
identified by using this checklist. Though helpful as a tool, the checklist is not an
absolute. Unique local situations that are difficult to account for will occasionally affect
the final product.

There are two general categories represented on the checklist. The first relates to
practices and methods. Positive attributes in this category could be labeled with terms
such as Clean, No Rust, Good Records, Precise Control, Consciences, Filter Changes,
Precise Work Methods, Dedicated Operators. If opposite characteristics are found in
practice, there exists an opportunity for improvement. In the end, this will result in
reduced contaminants in the product.

Facility attributes fall into the second category of items. We address items such as
radiant ovens, filter type and location, product protection enclosures, type of tack-off
machinery, dust containment methods, and dust removal in this category. In this area,
dirt reduction type facilities will pay off for the company in the form of a clean,
contaminant free product.

The checklist may be used to determine the areas in which practices can be improved
in the short term and in the long term, the directions that could be considered for
subsequent facilities improvements.

Appendices
Related Materials
Appendices include the following related materials:

• Appendix A: Contaminant troubleshooting

Revised: 10/12/00 Page 3-1

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 3 - Plant Area Checklists

GM STANDARD COATINGS SYSTEM

STRIP
PHOSPHATE ELPO ACCUMULATOR

ZINC PHOS CATHODIC TRANSFER

PRE-CLEAN ELECTRO RINSE
IMMERSION SYSTEM TO FLOOR OVEN
SPRAY SYSTEM DEPOSITION CONVEYOR

SEAL ELPO SAND

MANUAL ROBOTIC UNDERBODY MANUAL

PULL OFF SEAL PVC ELPO SAND
SEAL SEAL
OPTIONAL OPTIONAL

OFF-LINE PULL OFF

REPROCESS
STRIP
PRIMER SURFACER ACCUMULATOR SAND

PRIMER MANUAL
SURFACE SURFACER FLASH MOIST SAND PULL OFF
PREP OVEN BLOW-OFF OPERATIONS
BOOTH DECK

STRIP
ACCUMULATOR TOP COAT

HEATED BASE SURFACE

OVEN FLASH CLEAR COAT COAT
FLASH PREP

FINESSE NOT OK RERUN SAND

GENERAL MISC. OK BANK/ HEAVY SAND

CONFIRMATION
ASSEMBLY OPERATIONS SEQUENCER

SPOT RERUN
FINAL LINE
PAINT
REPROCESS

PANEL SWAP

Revised: 10/12/00 Page 3-2

 ELPO DEFECT SANDING

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
CLOTHING SANDPAPER BLOW-OFF
WORN TRAINING AFTER SAND
BACK-UP
GLOVES PADS DUST
REMOVAL
LINT-FREE ADHESIVE
JUDGMENT
COVERALLS APPLICATION PRODUCTION
OF JIG/FIXTURES
REGULAR
COVERALLS ADHESIVE
Paint Shop Contamination Control Guidelines

STREET WIPING
CLOTHES MATERIALS

DEFECT
VARIATION
AREA
DRY SAND
CLEANLINESS
WITH D.A.
SANDER HAND
OPEN
SCUFF
DOORS
AMOUNT SAND
OF SANDING PERSONAL
GRIT OF
COOLING
VACUUM PAPER USED
FANS
ATTACHED DUST
REMOVAL
FEED-BACK
DUST
TO REDUCE
DEFECTS AIR REMOVAL
OPEN AREA
METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-3
 BODY SHOP

PERSON MATERIALS EQUIPMENT

Paint Engineering

DRIED ON DRIED

Revised: 10/12/00
GLOVES CLEANERS TYPE STEAM
DIRT DIRT DRAWING
COMPOUND USED
OTHER
CLEANLINESS
EXTERIOR
CLEANLINESS HIGH PRESSURE
INTERIOR CHALK MARKS WATER

WELD METAL BRAZING WELD FLASH BODY SHOP

BALLS FILINGS WASHER
CONDITION OF
POSITION EXTERIOR CLEAN NOZZLES
GRIND
Paint Shop Contamination Control Guidelines

FILING
SEALER SLIVERS SLIVERS
GRIND TEMPERATURE CLEANLINESS
AMOUNT MARKS
CONSISTENT LOOSE

FLANGES

TIGHT
DIRT
VARIATION
TIME FACTOR
BEFORE
PHOSPHATE
CONVEYOR
CONDITION

CONVEYOR
TRANSFER

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-4
 PHOSPHATE

PERSON MATERIALS EQUIPMENT

FACTUAL SEEDS FUNCTION
RECORD GALVANIZED FIXTURES
Paint Engineering

Revised: 10/12/00
KEEPING
CLEANLINESS
CONTINUOUS DIP/SPRAY
UNDERSTANDS
SELF SYSTEM CONDUCTIVITY
EVALUATION OF DRAG-IN
POWDERS NUMBER OF
OPERATIONAL
TRAINING & STAGES
SEQUENCE
SKILL LEVEL CHEMICALS CLEANLINESS
OF DRAG-IN
HYGIENE LIQUIDS CONDITIONS OF
PROBLEM TANK LININGS
SOLVING
RELIEF EFFECTIVENESS INTERIOR
Paint Shop Contamination Control Guidelines

SCHEDULE CONDITION OF
FILTER UNIT
RESPONSE SYSTEM EXTERIOR
TO DESIGN CARRIER
PROBLEMS CLOTHING CLEANLINESS

CAPACITY CARRIER
PRODUCT HEAD GEAR
DESIGN
FROM BODY DIRT
SHOP FILTER PUMP
VARIATION
CHANGES PRESSURES

INVENTORY PRODUCT
INTERIOR
OF UNIT RECORD PROTECTION
KEEPING

BATH CONDUCTIVITY TIME FACTOR

PRE-PHOSPHATE TO ELPO
CONSTANTS
CLEANING
MAINTENANCE
VIBRATION
EXTERIOR HOUSEKEEPING
OF UNIT OVERHEAD
CONDITION OF
NOZZLES CONVEYOR
STATISTICAL
DRIP PANS
DEFECT
EFFECTIVE
TRACKING CONDITION
BY AREA/PROCESS

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-5
 ELPO OVEN

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
SMALL SIZE IN RELATION
TRAINING TO PRODUCT
FLOOR
LARGE
CONVEYOR RADIANT ZONES
FOCUSED TYPE
CLEANING DESIGN
DRIP FRESH AIR
PANS LOW RATES
VELOCITY
OVERHEAD CONVECTION
Paint Shop Contamination Control Guidelines

HIGH
FLAT FRESH VELOCITY
TYPE
MECHANICAL AIR
FILTERS
FILTRATION

AIR SEALS RECIRCULATION

INTEGRITY
A-TYPE CONDITION

RUST
PRODUCT DIRT
FROM ELPO BY
VARIATION
FILTER SECTION
P CHARTING BASED AIR FILTRATION
FILTER ON DATA INTO ENCLOSURE
CHANGES
METHOD
RECORD
KEEPING CLEANING
OVEN
SPC OF BASED LOCATION
DIRT PARTICLES ON FIXED
SCHEDULE
CLEANING
SCHEDULE

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-6
 SEALER APPLICATION

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
HYGIENE

TRAINING TEMPERATURE

RELIEF VISCOSITY
SCHEDULE
SPRAY
SKILL STABILITY
LEVEL
FLOW
LINT FREE BRUSH
Paint Shop Contamination Control Guidelines

APRONS COVERALLS

CLOTHING THUMBGRADE
WORN
SEALER WAND
CLEAN-UP REGULAR HAND
GLOVES COVERALLS OIL

STREET
CONDITION OF CLOTHES
DIRT
PRODUCT FROM VARIATION
ELPO SANDING
CLEAN-UP
REQUIRED WIPING
MATERIALS
TEAM
SOLVENT PERFORMANCE RESULTANT
CLEAN-UP IN-STATION FEEDBACK VISCOSITY
CLEAN-UP
END OF
LINE

TECHNIQUE AREA SPECIFIC

RESULTING STATISTICAL
IN CONSTANT CHARTING
APPLICATION
METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-7
 SEALER OVEN

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
SMALL SIZE IN RELATION
TO PRODUCT
FLOOR
LARGE
CONVEYOR RADIANT ZONES
TYPE
DESIGN
DRIP FRESH AIR
PANS LOW RATES
VELOCITY
OVERHEAD CONVECTION
Paint Shop Contamination Control Guidelines

HIGH
FLAT FRESH VELOCITY
TYPE
MECHANICAL AIR
FILTERS
FILTRATION

AIR SEALS RECIRCULATION

INTEGRITY
A-TYPE CONDITION

RUST
PRODUCT FROM DIRT
SEALER LINE BY
VARIATION
FILTER SECTION
P CHARTING BASED AIR FILTRATION
FILTER ON DATA INTO ENCLOSURE
CHANGES
METHOD
RECORD
KEEPING CLEANING
OVEN
BASED LOCATION
SPC OF ON FIXED
DIRT PARTICLES SCHEDULE
CLEANING
SCHEDULE

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-8
 BOOTH AIR SUPPLY SYSTEM
PRIMER, TOPCOAT, REPAIR
Paint Engineering

Revised: 10/12/00
PERSON MATERIALS EQUIPMENT
TYPE PUSH-PULL
SYSTEM
WATER
CLEANLINESS QUALITY FILTER
CHECKED
REGULARLY LOCATION

TRAINED HUMIDIFICATION

MAINTENANCE REPAIR NUMBER OF

FUNCTION CONTROL
RESPONSE FILTER FILTER BANKS
OF SYSTEM
Paint Shop Contamination Control Guidelines

BANK
RUST INTEGRITY TYPE OF
ABILITY
TO CORRECT REDUCING FILTERS
INSTALLED
EMPOWERMENT
FILTER
RUST
FUNCTIONAL

QUALITY

QUALITY OF DIRT
INCOMING AIR SILICONE
VARIATION
FILTER FILTER BANK INTERVAL POWDER
CHANGES P CHARTING
BURNER DANDELION
MAINTENANCE FIBERS
AIR QUALITY
EFFECTIVENESS
TEST CHECK
& REPAIR ADEQUATE COTTONWOOD
WASH HYDROCARBONS FIBERS
BANK AFTER SUPPLY
AREA IN AIR
REPLACEMENT AIR VOLUME
CONTROL
BASED ON SNOW
P
CLEANING BOOTH WEATHER
SCHEDULE BALANCE
RUST

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-9
 PRIMER TACK-OFF

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
SOLVENT COMPRESSED
CLOTHES WIPERS
CONTAINER AIR QUALITY
PACKAGING
STREET CLEANLINESS
TACK
CLOTHES
MARKS
ARTICULATED
HEAD INVENTORY BLOW-OFF
GEAR
LINT
REGULAR LOCATION
Paint Shop Contamination Control Guidelines

COVERALLS HYGIENE
PROGRAMMING
LINT-FREE TRAINING
REGULARLY
COVERALLS CLEANED
SKILL
LEVEL
GLOVES

DEFECT
VARIATION
WIPING
TECHNIQUE GENERAL
BLOW-OFF AREA
SNAG TECHNIQUE
AREAS BOOTH
QUALITY
AREAS
AREA BLOWN OFF
COVERED DOWNDRAFT

REPEATABILITY AIR SUPPLY

REPEATABILITY

STROKE SEQUENCE

REPLACEMENT
FREQUENCY

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-10
 PRIMER BOOTH

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
CLOTHING PRODUCTION BOOTH WALLS COMPRESSED AIR
CLEANING PIPING
CHANGE BARE METAL FILTER TYPING
FREQUENCY TRAINING TYPE
AIR
LINT-FREE PAINT QUALITY FILTER QUALITY
SKILL
COVERALLS STAGES
PAINT FILTRATION FILTER
OPERATOR LOCATION
GLOVES
OPERATOR CARRIER APPLICATION
HEAD TRAINING MACHINE
OVER MACHINERY
GEAR JIGS
Paint Shop Contamination Control Guidelines

NUMBER OF PRODUCT CLEANING

BLOW-OFF PEOPLE MACHINERY
GUNS
BEFORE CLEANING
HYGIENE BELLS
BOOTH ENTRY AIR FLOW
RELIEF OBSTRUCTION
SCHEDULE
DEFECT
CAP/GUN VARIATION
COLOR SPRAY GUN
CHANGE OR CLEANLINESS
SCHEDULE
MAINTENANCE BOOTH
GUN GUN BALANCE
MAINTENANCE FREQUENCY MAINTENANCE
AIR FLOW
CAP TACK RAG MACHINE
QUALITY FIBER CONTRIBUTION BOOTH
PROTECTION DOORS CLOSED
HOSE FOR PIECES
PATTERN LIGHTING
CLEANLINESS
RAIL OLD
BOOTH DIRT OVERSPRAY
CLEANING
HOSE
CLEANLINESS MOVEMENT
OF MACHINES INTERIOR
CUT-TIN EXCESS OIL
ATOMIZING
AIR
METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-11
 PRIMER OVEN

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
SMALL SIZE IN RELATION
TRAINING TO PRODUCT
FLOOR
LARGE
CONVEYOR RADIANT ZONE
FOCUSED TYPE
CLEANING DESIGN
DRIP FRESH AIR
PANS LOW RATES
VELOCITY
OVERHEAD CONVECTION
Paint Shop Contamination Control Guidelines

HIGH
FLAT FRESH VELOCITY
TYPE
MECHANICAL AIR
FILTERS POINT
FILTRATION OF USE
AIR SEALS RECIRCULATION
INTEGRITY
A-TYPE CONDITION
CONDITION OF RUST
DIRT
PRODUCT FROM VARIATION
PRIME BOOTH BY
FILTER SECTION
P CHARTING BASED AIR FILTRATION
FILTER ON DATA INTO ENCLOSURE
CHANGES
METHOD
RECORD
KEEPING CLEANING
OVEN
SPC BASED LOCATION
OF DIRT ON FIXED
PARTICLES SCHEDULE
CLEANING
SCHEDULE

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-12
 PRIMER SANDING

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
BOOTH
HYGIENE

PACKAGING ADHESIVE DOWNDRAFT

WIPING
MATERIALS SANDPAPER AREA

TRAINING LINT
POTENTIAL WET OPEN
FLOOR
Paint Shop Contamination Control Guidelines

GLOVES
CLOTHING
APRON
SKILL LINT-FREE AREA BLOW-OFF
LEVEL COVERALLS SANDED
WET
REGULAR SAND
COVERALLS

STREET WASH
CONDITION OF CLOTHES
DIRT
PRODUCT FROM VARIATION
PRIME OVEN POWER
SANDER
DRY SAND

HAND
PROXIMITY TO
TECHNIQUES GRIT OTHER PROCESSES
LIGHTING
CLEAN MOIST
UP SAND HAND TIME/PATH
TO TOPCOAT

WIPE MATERIALS
WASH DRY

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-13
 TOPCOAT TACK-OFF

PERSON MATERIALS MATERIALS

Paint Engineering

Revised: 10/12/00
SOLVENT FEATHER
WIPERS
CLOTHING CONTAINER DUSTER
PACKAGING DIRT PICK-UP
STREET CLEANLINESS DE-IONIZED FEATHER
TACK
CLOTHES LIFE
MARKS
PROGRAMMING
HEAD INVENTORY PROPER
AGE PROGRAMMING
GEAR
LINT
PROPER
REGULAR FEATHER
Paint Shop Contamination Control Guidelines

COVERALLS HYGIENE CRUCH

LINT-FREE TRAINING
FEATHER
COVERALLS QUALITY
SKILL
LEVEL
GLOVES

DEFECT
VARIATION
WIPING
TECHNIQUE GENERAL
BLOW-OFF AREA
AREA TECHNIQUE
COVERED DOWNDRAFT

FOLDING AREAS
TECHNIQUE BLOWN OFF

COMPRESSED AIR SUPPLY

REPLACEMENT
AIR QUALITY
FREQUENCY BOOTH
QUALITY
STROKE LOCATION

SNAG SEQUENCE
AREAS

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-14
 TOPCOAT BOOTH

PERSON MATERIALS MATERIALS

Paint Engineering

Revised: 10/12/00
CLOTHING PRODUCTION BOOTH WALLS COMPRESSED AIR
CLEANING AIR
LINT-FREE BARE METAL FILTER
QUALITY
COVERALLS TYPE
TRAINING
FILTER
BLOW-OFF PAINT QUALITY STAGES FILTER
SKILL LOCATION
BEFORE PIPING
BOOTH ENTRY OPERATOR PAINT FILTRATION
TYPE
CHANGE OPERATOR CARRIER APPLICATION
FREQUENCY TRAINING BELLS AIR FLOW
JIGS
Paint Shop Contamination Control Guidelines

NUMBER OF GUNS OBSTRUCTION

HEAD PEOPLE
GEAR MACHINE MACHINERY
HYGIENE OVER CLEANING
GLOVES PRODUCT MACHINERY
CLEANING

DEFECT
VARIATION
SPRAY GUN
SCHEDULE CLEANLINESS
BOOTH
GUN ATOMIZING GUN BALANCE
MAINTENANCE AIR MAINTENANCE
AIR FLOW
PATTERN CAP MACHINE
QUALITY CONTRIBUTION BOOTH
COLOR OLD DOORS CLOSED
CHANGE OR METAL OVERSPRAY
MAINTENANCE PIECES LIGHTING
PROTECTION
BOOTH RAIL FOR PIECES
CLEANING DIRT
TACK RAG HOSE
HOSE FIBER MOVEMENT
CLEANLINESS INTERIOR
CUT-IN
CLEANLINESS
OF MACHINES METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-15
 TOPCOAT OVEN

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
SMALL SIZE IN RELATION
TRAINING TO PRODUCT
FLOOR
LARGE
CONVEYOR RADIANT ZONE
FOCUSED TYPE
CLEANING DESIGN
DRIP FRESH AIR
PANS LOW RATES
VELOCITY
OVERHEAD CONVECTION
Paint Shop Contamination Control Guidelines

HIGH
FLAT FRESH VELOCITY
TYPE
MECHANICAL AIR
FILTERS POINT
FILTRATION OF USE
AIR SEALS RECIRCULATION
INTEGRITY
A-TYPE CONDITION
CONDITION OF RUST
DIRT
PRODUCT FROM VARIATION
TOPCOAT BOOTH BY
FILTER SECTION
P CHARTING BASED AIR FILTRATION
FILTER ON DATA INTO ENCLOSURE
CHANGES
METHOD
RECORD
KEEPING CLEANING
OVEN
SPC BASED LOCATION
OF DIRT ON FIXED
PARTICLES SCHEDULE
CLEANING
SCHEDULE

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-16
 INSPECT, FINESSE, AND POLISH

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
HYGIENE

SANDPAPER

JUDGMENT TRAINING
POLISH POLISHER
SKILL COMPOUND

VISION CONSISTENT
STANDARD SILICONE ROTARY
ORBITAL
Paint Shop Contamination Control Guidelines

APRONS
CLOTHING
GLOVES
CLARITY LINT-FREE
WIPING
WEAR
MATERIALS
STREET
TYPE
WEAR

HEAD
CONDITION OF GEAR
DIRT
PRODUCT FROM VARIATION
TOPCOAT OVEN SUMMARY
CONSISTENT
AMONG
AMONG LIGHTING
INSPECTORS
RECORD
KEEPING SAME
CONTAMINATION
VEHICLE
FEEDBACK FOLLOWING
INSPECTION TO TOPCOAT
STANDARD PROCESS

OTHER
TECHNIQUE
POSTED VEHICLE
VEHI
SPECIFICATION
FINESSE PROXIMITY
PROXIMITY TO
CONTAMINATION OTHER
THOROUGH OTHER AREAS OPERATIONS

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-17
 REPAIR/TWO-TONE

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
HYGIENE

ADHESIVE

MASKING
MATERIALS
APRON

TRAINING GLOVES CLOTHING

HEAD
GEAR LINT-FREE SANDPAPER
Paint Shop Contamination Control Guidelines

COVERALLS

REGULAR
SKILL ADHESIVE
COVERALLS
LEVEL
STREET
CLOTHES

CONDITION OF DIRT
PRODUCT FROM VARIATION
PRIME OVEN POWER
SANDERS
BLOW-OFF
CLEANED
UP
GRIT
USED PATH TO
REPAINT AREA
SAND MASKING
TAPE
PATH FROM
MANUAL SAND AREA
CLEANED INSPECTION
DESIGN
UP
CLEANED UP PROXIMITY TO
BEFORE OTHER OPERATIONS
REPAINT

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-18
 REPAIR/TWO-TONE BOOTH

PERSON MATERIALS MATERIALS FILTER

TYPE
Paint Engineering

Revised: 10/12/00
RELIEF HYGIENE WALL PAINT
SCHEDULE CONDITION COMPRESSED AIR
PRODUCTION BOOTH WALLS
CLOTHING CLEANING FILTER PIPING
BARE METAL LOCATION TYPE
LINT-FREE TRAINING
COVERALLS CIRCULATION
FOCUSED SYSTEM FUNCTION FILTER
STAGES AIR
BLOW-OFF CLEANING QUALITY AIR FLOW
PAINT QUALITY OBSTRUCTION
BEFORE SKILL MACHINE
BOOTH ENTRY OVER
OPERATOR PAINT FILTRATION MACHINERY
PRODUCT
CHANGE CLEANING
Paint Shop Contamination Control Guidelines

FREQUENCY OPERATOR CARRIER

TRAINING APPLICATION
JIGS
HEAD SEQUENCE BELLS
NUMBER OF
GEAR PEOPLE MACHINERY
GUNS
SEQUENCE
GLOVES
DEFECT
CAP/GUN GUN VARIATION
CLEANLINESS MAINTENANCE
GUN BOOTH
PATTERN MAINTENANCE SPRAY GUN DOORS CLOSED
CAP PROTECTION CLEANLINESS BOOTH
SCHEDULE FOR PIECES
QUALITY HOSE ERRATIC
FREQUENCY MOVEMENT
ATOMIZING BOOTH
AIR HOSE BALANCE
RUB
COLOR OLD BOOTH
CHANGE OR OVER MACHINE LIGHTLY
MAINTENANCE SPRAY CONTRIBUTION POSITIVE
HOSE
TACK RAG METAL EXCESS
CLEANLINESS LIGHTING
FIBER PIECES OIL
RAIL CLEANLINESS
BOOTH INTERIOR FLASH-OFF
CLEANING CUT-TIN DIRT ZONE
WET-PAN
AREA FLOOR
CLEANLINESS SPECIFIC
OF MACHINES SPC DATA CHARTING AIR FLOW

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-19
 REPAIR/TWO-TONE OVEN

PERSON MATERIALS EQUIPMENT

Paint Engineering

Revised: 10/12/00
SMALL SIZE IN RELATION
TRAINING TO PRODUCT
FLOOR
LARGE
CONVEYOR RADIANT ZONE
FOCUSED TYPE
CLEANING DESIGN
DRIP FRESH AIR
PANS LOW RATES
VELOCITY
OVERHEAD CONVECTION
Paint Shop Contamination Control Guidelines

HIGH
FLAT FRESH VELOCITY
TYPE
MECHANICAL AIR
FILTERS POINT
FILTRATION OF USE
AIR SEALS RECIRCULATION
INTEGRITY
A-TYPE CONDITION
CONDITION OF RUST
DIRT
PRODUCT FROM VARIATION
REPAIR BOOTH BY
FILTER SECTION
P CHARTING BASED AIR FILTRATION
FILTER ON DATA INTO ENCLOSURE
CHANGES
METHOD
RECORD
KEEPING CLEANING
OVEN
SPC BASED LOCATION
OF DIRT ON FIXED
PARTICLES SCHEDULE
CLEANING
SCHEDULE

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-20
 PAINT CIRCULATION SYSTEM

PERSON MATERIALS EQUIPMENT

SYSTEM OILS
Paint Engineering

Revised: 10/12/00
FUNCTION LUBRICANT MATERIAL
HANDLING HANDLING
HYGIENE TRAINING
CONTAINERS EQUIPMENT
CLEAN
METHODS PAINT
EMPOWERMENT RESTRICTED BALANCE
STORAGE TO AREA VELOCITY
CONTAINERS
HANDLING CIRCULATION
NUMBER OF SYSTEM
PEOPLE SOLVENT
STORAGE RESTRICTORS
SPEED
GLOVES REGULATORS
CLOTHING AGITATORS SOAKER DEDICATED GUNS
Paint Shop Contamination Control Guidelines

APRON BOX
LINT-FREE QUICK CHANGE
PADDLE
COVERALLS
SIZE SUPPLY TYPE FIBERS
REGULAR
COVERALLS LUBRICANT FILTRATION
HEAD GEAR RETURN FLOW RATE

STREET CLOTHES DIRT

CLEAN CHECK VARIATION
FILTER
PROCEDURE
METHODS
HANDLING
HUMIDITY
HANDLING PAINT
CRATER DOORS
TANKS LINT CHECK MOPS KEPT CLOSED
CLOSED
CLEANLINESS WIPER
SPILL ROOM
FILTER
CHANGE/ CLEAN-UP
STORAGE POSITIVE
TIME CLEAN PUMP TO OUTSIDE AIR SUPPLY
PRESSURE FILTERS

INVENTORY GAUGE
CHECKS
LIGHTING
RECORDS

TEMPERATURE DIRT EXTERNAL ACCESS

VISCOSITY

METHODS ENVIRONMENT
Chapter 3 - Plant Area Checklists

Page 3-21
 GENERAL PAINT SHOP ENVIRONMENT

MATERIAL
PERSON MATERIALS EQUIPMENT HANDLING
FUNCTION
Paint Engineering

CRATER

Revised: 10/12/00
CONTAMINATION
PROGRAM MANUAL CONSCIOUS
HYGIENE VELOCITY VOLUME
MANAGEMENT
SUPPORT SMOKING ENTRANCE
BLOW-OFFS CHAMBERS
LINT-FREE EATING
TRAFFIC
HEAD GEAR
CRATERS POWDERS DOWN PATTERNS
NON- DRAFT
100% PRODUCTIVE SEALED
LINT-FREE MATERIALS PRODUCTION FLOORS
WEAR MATERIAL
LINT PACKAGING LIQUIDS NOT SEALED FINAL
FILTRATION
RESTRICTED MATERIAL OPERATION FUNCTION
Paint Shop Contamination Control Guidelines

USED AIR SUPPLY

NUMBER OF
RUST SILICONE AIR HUMIDIFICATION
PEOPLE
RESISTANT CURTAINS
TEMPERATURE
CLEANLINESS VENTILATION
LEVEL COOLING
TOURS FILTERED
PERSONNEL
DEEP CLEAN
DIRT
PRACTICES 24 HRS
VARIATION
POSITIVE POSITIVE
MAINTENANCE SEGREGATED
VENTILATION

STORAGE HUMIDIFICATION
HANDLING ISOLATED FROM
CONTROLLED
OTHER SHOPS
POWDERS
DUST PAINT EQUIPMENT PERSONNEL
SHOP
PHILOSOPHY RESTRICTED
CLEANLINESS ACCESS
ENTRY TRAINING POSITIVE AWAY
PROCEDURE FROM VEHICLES
SEGREGATED
LUNCH NEGATIVE TO INTERNAL
AREAS CONTAIN HEAT VENTILATION
SHOES AND FUMES
FILTERS
TEMPERATURE
SEPARATE
IN BOOTH RECORD
KEEPING HUMIDITY
CLEANING EXTERNAL
OTHER
METHODS ENVIRONMENT INDUSTRIES
Chapter 3 - Plant Area Checklists

Page 3-22
Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

CHAPTER 4 – PROBLEM SOLVING FOR CONTAMINATION CONTROL

Rarely, if ever, does the Zen approach to problem solving work. Nor do problems go
away if you just ignore them long enough. Most problems require some sort of plan.
This chapter details the steps for systematic problem solving in paint contamination
control. The problem solving methods used are based on the Quality Network Problem
Solving Model. This customized version of the Model outlines the methods for isolating
a contaminant, identifying the source, and reducing or eliminating future contamination.

To build skills in specific areas mentioned in this section, contact the appropriate
training coordinator or go to the GMU web site for GMU course descriptions and
registration.

PROBLEM SOLVING
FOR CUSTOMER SATISFACTION
AND ENTHUSIASM
CONTINUOUS QUALITY
INSTITUTIONALIZE OPPORTUNITY
IMPROVEMENT

T
EN
EV
SE

R
LE

P 5.
CT

1.
EVALUATE
IDENTIFY

PEOPLE
&
TEAMWORK 2.
4.
ANALYZE
IMPLEMENT

CO 3. N
RR PLAN AI
E CT ONT
C

Revised: 10/12/00 Page 4-1

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

PURPOSE OF THE PROBLEM SOLVING MODEL

DEFINITION

There is a chasm between your present situation and where you want to be. This chasm
is your problem. How you choose to bridge the gap and arrive at the other side is your
solution. Problems are opportunities for continuous quality improvement.

The objective of this section is to provide you with the Contamination Control Problem
Solving Model as a tool for defining and analyzing contaminant problems, finding their
root causes, and implementing permanent solutions. By bridging the gap, we will
continually improve customer enthusiasm.

There are four concise and logical

tasks in the Problem Solving Model. PROBLEM SOLVING
FOR CUSTOMER SATISFACTION
1. Select Contaminant Problem
2. Contain Contaminant AND ENTHUSIASM
CONTINUOUS QUALITY
3. Correct Contaminant INSTITUTIONALIZE
IMPROVEMENT
OPPORTUNITY

4. Prevent Contaminant T
EN
EV

SE
PR

LE
5.

CT
1.
This model, based on the Quality EVALUATE
IDENTIFY

Network Problem Solving Process, PEOPLE

&
TEAMWORK 2.
4.
is very flexible and can be applied IMPLEMENT
ANALYZE

to a wide range of problems CO

R
RE
3.
PLAN AI
N
CT NT
CO
including quality, safety, and
systems.

CHALLENGES

Everything from sports to warfare is based on strategy. The manufacturing environment

is no different. To effectively resolve our problems, we need to systematically break
them down to their base element and go from there. Common mistakes which occur in
the absence of a problem-solving strategy are:

• Jumping to conclusions:
We think we know the answer to a problem before we look at all of the information. If
you jump to an uninformed conclusion, it is very likely you will be jumping to the
wrong conclusion
• Not working on the root cause:
Sometimes we will work on an effect because the root cause has not been identified.
Treating the symptom is useless unless we find the cause
• Not gathering all critical data:
We try to hurry the process, take shortcuts, and miss key data that will impact the
outcome of our problem solving efforts

Revised: 10/12/00 Page 4-2

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

• Working on problems that are too large or general:

We take on a problem that cannot be solved because it is not defined clearly or is
the responsibility of personnel outside of our functional work area
• Not involving key people:
We analyze a problem without involving the personnel most likely to have a
significant insight on it
• Lack of a planned solution:
We create a solution that does not specify ownership, resources required, timing,
and responsibility

When used consistently, the Contamination Control Problem Solving Model can enable
paint personnel to avoid most of these pitfalls.

BENEFITS

The model helps us to:

• Communicate efficiently using one common “problem solving” language

• Describe the problem accurately
• Contain the problem
• Analyze the problem and its impact
• Develop a solution
• Implement and validate the solution
• Make solutions permanent

An additional benefit of using the model is that all personnel have the opportunity to be
involved in problem solving, which can have a positive impact on:

• Work environment
• Quality of the finished product and service quality
• Cost
• Meeting or surpassing best-in-segment quality for all products and related services
• Total employee involvement/focus on achieving organizational goals
• Job security

Revised: 10/12/00 Page 4-3

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

STEPS OF THE CONTAMINATION CONTROL

PROBLEM SOLVING MODEL
There are four steps in the Contamination Control Problem Solving Model as defined
below:

Step 1: Select Contaminant

1.1 Select a Problem PROBLEM SOLVING
1.2 Write a Problem Statement
FOR CUSTOMER SATISFACTION
1.3 Develop a Goal Statement
AND ENTHUSIASM
CONTINUOUS QUALITY
Step 2: Contain Contaminant INSTITUTIONALIZE
IMPROVEMENT
OPPORTUNITY

2.1 Contain the Problem T

EN
EV

SE
PR

LE
5.

CT
1.

Step 3: Correct Contaminant EVALUATE

IDENTIFY

3.1 Collect Data PEOPLE

&
TEAMWORK 2.
4.
3.2 Perform Cause Analysis IMPLEMENT
ANALYZE

3.3 Identify Root Cause CO

R
RE
3.
PLAN
NT
AI
N
C
CO
3.4 Generate Solution Alternatives T

3.5 Identify Selection Criteria

3.6 Select Best Solution
3.7 Test the Solution
3.8 Evaluate the Data
3.9 Document Test Results

Step 4: Prevent Contamination

4.1 Execute Error Proofing
4.2 Obtain Approvals
4.3 Verify Solution
4.4 Store All Documents and Records
4.5 Institutionalize the Solution
4.6 Communicate; Share Best Practices

Revised: 10/12/00 Page 4-4

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

IMPLEMENTING THE CONTAMINATION CONTROL

PROBLEM SOLVING MODEL

STEP 1: SELECT CONTAMINANT

In Step 1, the contamination analyst collects and organizes information to determine the
gap between where we are and where we need to be in the future.

PROBLEM SOLVING
FOR CUSTOMER SATISFACTION
AND ENTHUSIASM
CONTINUOUS QUALITY
INSTITUTIONALIZE OPPORTUNITY
IMPROVEMENT

T
EN
EV
SE

R
LE

P 5.
CT

1.
EVALUATE
IDENTIFY

PEOPLE
&
TEAMWORK 2.
4.
ANALYZE
IMPLEMENT

CO 3. N
RR PLAN AI
E CT NT
CO

1.1 Select a Problem

Before selecting a problem, answer the following questions:

1. Is the problem a priority?

2. Does it affect customer satisfaction?
3. Is the solution to the problem vital?
4. How often does this problem occur?
5. Is the problem within our control to solve? Do we have the resources to solve it?
(Time, people, money, etc.)

The problems with the greatest impact should be addressed first.

Revised: 10/12/00 Page 4-5

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

EXAMPLE:

One GM assembly plant recorded the following problem:

1.1 Select a problem 1.2 Write a problem 1.3 Develop a goal

statement statement

Where you are: The gap: Where you want to be:

Craters appeared on both
the C and M Systems,
both shifts on 3/10/99
causing downtime due to
excessive repair, scrap,
and holding to finesse
craters. There have been
25 incidents affecting 9
production days from
3/10/99 to 4/1/99.

Training Tips
Root Cause Analysis Courses

For more information and skills consider taking these courses:

COURSE NO. COURSE TITLE

69 Root Cause and Decision Analysis

1.2 Write a Problem Statement

To help us focus on a problem, our next step is to write a problem statement.

• State the problem completely and accurately

• Describe object affected
• Use facts and data
• Use short statements
• Never include the word “and”
• Use terms that are specific and measurable

Revised: 10/12/00 Page 4-6

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

EXAMPLE:

See the example of the problem statement below.

1.1 Select a problem 1.2 Write a problem 1.3 Develop a goal

statement statement

Where you are: The gap: Where you want to be:

Craters appeared on both • Production running
the C and M Systems,
• First buy rate down
both shifts on 3/10/99
40%
causing downtime due to
excessive repair, scrap, • Second run rate = 90%
and holding to finesse
craters. There have been
25 incidents affecting 9
production days from
3/10/99 to 4/1/99.

1.3 Develop a Goal Statement

Now that we have defined the problem, we need to outline where we are going with it.
Our next step is to write a goal statement. An effective goal statement must include a
way to measure improvement and a timeframe during which the measurement will
occur.

1. Increase first buy rate to 90%.

2. Decrease incidence of cratering.
3. Achieve goal percentages within four weeks.

A goal statement is a mirror image of a problem statement. All Contamination Control

Team members should understand exactly what has to be accomplished.

Revised: 10/12/00 Page 4-7

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

EXAMPLE:

See the goal statement below.

1.1 Select a problem 1.2 Write a problem 1.3 Develop a goal

statement statement

Where you are: The gap: Where you want to be:

Craters appeared on both • Production running • Increase first by rate to
the C and M Systems, 90%
• First buy rate down
both shifts on 3/10/99
40% • Decrease incidence of
causing downtime due to
cratering
excessive repair, scrap, • Second run rate = 90%
and holding to finesse • Achieve goal
craters. There have been percentages within four
25 incidents affecting 9 weeks
production days from
3/10/99 to 4/1/99.

Revised: 10/12/00 Page 4-8

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

STEP 2: CONTAIN CONTAMINANT

2.1 Contain the Problem

When a problem is identified, you must take immediate action to contain it. Containment
is only a temporary solution. You will continue to work through the problem solving
model to identify and implement a permanent solution.

PROBLEM SOLVING
FOR CUSTOMER SATISFACTION
AND ENTHUSIASM
CONTINUOUS QUALITY
INSTITUTIONALIZE OPPORTUNITY
IMPROVEMENT

T
EN
EV
SE

R
LE

P 5.
CT

1.
EVALUATE
IDENTIFY

PEOPLE
&
TEAMWORK 2.
4.
ANALYZE
IMPLEMENT

CO 3. N
RR PLAN AI
EC NT
T CO

During containment, collect and organize information to determine the gap between

• Where we are now

• Where we need to be in the future

Examine the problem and gather all the facts:

• What happened?
• What did not happen?
• Where did it happen?
• Where did it not happen?
• When did it happen?
• When did it not happen?

Revised: 10/12/00 Page 4-9

Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

EXAMPLE:

The GM assembly plant in the example contained the crater problem by:
1. Changing all paint shop compressed air filters
2. Conducting an environmental screening of air-houses, spray booths, ovens and prep
areas for potential contamination sources
3. Screening all consumables: paints, solvents, wipers, sandpaper, etc.

STEP 3: CORRECT CONTAMINANT

In step 3, you will determine the most appropriate permanent change to eliminate the
root cause of a problem.

PROBLEM SOLVING
FOR CUSTOMER SATISFACTION
AND ENTHUSIASM
CONTINUOUS QUALITY
INSTITUTIONALIZE OPPORTUNITY
IMPROVEMENT

NT
VE
SE

E
PR
LE

5.
C

1.
T

EVALUATE
IDENTIFY

PEOPLE
&
TEAMWORK 2.
4.
ANALYZE
IMPLEMENT

CO 3. N
RR PLAN AI
EC NT
T CO

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

3.1 Collect Data

Okay, we have defined the problem and contained it. Now we need to find its source
and put a permanent end to it. Information is our best weapon in this struggle.
Determine which member(s) of the Contamination Control Team will be responsible for
gathering data, what type of data will be needed, and who will interpret it.

3.2 Perform Cause Analysis

There are three tools that are helpful in identifying root causes:

• The “Five Whys”

• Brainstorming
• Cause and Effect “Fishbone” Diagram

Tool Tips
Five Whys
By questioning each finding, we can systematically wade through the quagmire of
false leads to eventually find the root cause. Using this method, ask “Why?” as each
“layer” of a problem is stripped away. This will eventually reveal our problem’s root
cause.

Brainstorming
This tool allows for generation of solution ideas. All ideas are valuable during a
brainstorming session because even the “wild and crazy” ideas may spark workable
solutions. Quantity – not quality – is the goal of a brainstorming session.

Pareto Charts
Pareto Charts are used to:
• Identify types of defects
• Identify frequency of defects
• Identify top 5 defects

Cause and Effect “Fishbone” Diagram

“Fishbone” Diagrams are used to:
• Organize information (systematic methodology)
• Provide structure to brainstorming sessions
• Analyze detail at each level of problem solving
• Document the problem solving process

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

3.2.1 Five Whys

A good method to identify a problem is to simply keep asking WHY? By continuing to

question why, you are more likely to find the root causes(s) of the problem.

3.2.2 Brainstorming

Brainstorming is a group activity. It taps ideas from all members. Criticism or evaluation
of ideas is not allowed during a brainstorming session. Quantity of ideas is encouraged.
Generating ideas that are “wild and crazy” is acceptable.

3.2.3 Cause and Effect Diagram

The objective of the Cause and Effect diagram is to identify and organize possible root
cause(s).

A C au se a nd E ffe ct D iag ra m R e pres en ts th e

R elation sh ip B etw ee n S o m e “E ffect” a nd A ll
P o ss ib le “C au ses.”

M AN M ETH O D M A TE R IA LS

O U TP U T

M EA S U R E M E N T M A C H IN E

The causes are usually grouped into five categories:

1. Machinery
2. Method
3. Materials
4. Measurement
5. Man

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

3.3 Identify Root Cause

To identify the root cause, you must:

• List data requirements

• Collect the data
• Analyze the data

When collecting data, you may want to include environmental issues that can impact the
problem solving effort. To achieve the desired state, determine which Quality Network
Action Strategies will be appropriate.

EXAMPLE:

In the crater problem, the root cause was identified as a slow contamination of
desiccant beds over a period of 3 ½ years by compressor oil. The leak itself was the
result of a change in the piping schematic which allowed an oil line to cross the air line
(piping was spliced). Also, the shields in the compressor were worn out.

3.4 Generate Solution Alternatives

Once we have collected all the information and settled on a potential cause, we need to
come up with a few alternative solutions. To any solution there will be roadblocks. It is
up to your team to identify those blocks and find ways around them.

EXAMPLE:

To resolve the crater problem, several solutions were implemented:

• The air compressor was repaired
• Filters were cleaned
• The air line affected by the oil leak was closed
• Carbon filter towers were installed to purify the compressed air. This solution was
implemented to prevent a recurrence of the problem

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

3.5 Identify Selection Criteria

To ensure the identified solution will achieve the Goal Statement, ask the following:

• Control
Is the solution within the control of the Contamination Control Team?
• Resources Required
Does the Contamination Control Team have the resources to implement the
solution?
• Payback
Is the payback greater than the cost?
• Buy-in
Is the solution acceptable?
• Quality
Will the customer be enthused?
• Performance
Will the solution prevent the problem from recurring?

EXAMPLE:

In the sample problem, the Contamination Control Team had the authority to
recommend a solution. They determined that carbon filter towers, although costly,
should be installed to ensure that the problem did not recur.

3.6 Select Best Solution

Review the list of solutions. Consider cost, time, and human resources needed.
Establish an effective measurement system to track progress. Identify the tasks, target
dates, and responsible people involved in the selected solution and contact all solution
stakeholders.

EXAMPLE:

The team presented the recommended solution with all cost, quality, and performance
factors to the World Wide Facilities. The recommendation was accepted and
implemented.

3.7 Test the Solution

Apply the solution to the problem. If the problem stops, dismantle the work you did to fix
the problem and determine whether or not it recurs. Apply the solution again and re-
examine the problem. This can be frustrating and time consuming, but it is the only way
to be sure. If the solution is successful, the problem has been eliminated and should not
recur. If the solution is unsuccessful and the problem recurs, true root cause has not
been identified.

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Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

EXAMPLE:

An outside firm was hired to monitor the effectiveness of the solution.

3.8 Evaluate the Data

Monitoring the process will ensure that the improvement and schedule agrees with the
goal statement. This will help you determine the effectiveness of the solution and its
likelihood of becoming the permanent answer. Document the results and issue interim
reports to the Contamination Control Team.

Communication Tips

Possible methods of communicating progress are:

• Verbal – communicate to the Contamination Control Team, supervisor, etc.

• Written reports/notices (in some plants)
• Discrepancy report
• Discuss progress at the Contamination Control Team meeting
• Review Best Practices
• Recognize efforts of team members
• Document/publish findings

3.9 Document Test Results

Documented test results should include answers to the following questions:

• Is customer satisfaction and enthusiasm achievable with this solution?

• Was the goal statement accomplished?
• Is the solution permanent?
• Would a combination of solution alternatives have been a better solution? Has this
been confirmed by testing?

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Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

EXAMPLE:

Testing, as well as all aspects of solution determination, were documented.

Documentation included tracking steps completed, recording time/contaminant counts,
and photographing and charting results.

STEP 4: PREVENT CONTAMINATION

Prevention means eliminating the possibility that a specific problem can occur or recur.

PROBLEM SOLVING
FOR CUSTOMER SATISFACTION
AND ENTHUSIASM
CONTINUOUS QUALITY
INSTITUTIONALIZE OPPORTUNITY
IMPROVEMENT

T
EN
EV
SE

R
LE

P 5. 1.
CT

EVALUATE IDENTIFY

PEOPLE
&
4. TEAMWORK 2.
IMPLEMENT ANALYZE

3.
CO
PLAN N
RR AI
EC NT
T CO

4.1 Execute Error Proofing

Congratulations! The problem was successfully resolved. The next step is to ensure that
the problem does not happen again. Error Proofing is the process of anticipating and
preventing problems that affect customer satisfaction. Error Proofing is a system of
preventing errors by:

• Designing products that cannot be manufactured or assembled incorrectly

• Using devices or inspection techniques that allow for detection of errors in the
planning stage and during the work process, rather than at the end of the process

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Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

EXAMPLE:

In the crater problem solution, the carbon filter towers were the chosen error proofing
method. Although cleaning and repairing the air compressor did solve the problem, it
was not a long-term solution. The carbon filter towers ensured that no further
contaminants would enter the compressed air.

4.2 Obtain Approvals

When change is required to implement a solution, you must obtain approvals for the
change(s). Internal changes such as modifying documents or changing Contamination
Control Team procedures must be communicated to everyone (other teams, suppliers,
engineers, etc.) who is affected by the change. Documentation and buy-in are vital for
all changes.

EXAMPLE:

Approval for purchase and installation of carbon towers was granted by World Wide
Facilities.

4.3 Verify Solution

Monitor the solution to ensure it has successfully solved the problem. Compare the
solution to the Goal Statement. Continue to collect the data at the beginning of the
process. If the problem does not recur during this time period, consider it a successful
resolution. Communicate results to stakeholders and thank them for their assistance.

EXAMPLE:

An outside company was hired to verify the effectiveness of the crater problem fix by
monitoring air content. The problem has not recurred.

4.4 Store All Documents and Records

Maintain all information that was gathered in the problem solving process. If another
problem occurs, all the facts and data will be readily available to determine if the
problem is new or recurring.

4.5 Institutionalize the Solution

By institutionalizing the solution, we make it part of our corporate culture. This makes
the solution common practice and reduces the chances of repeating the problem.

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Paint Shop Contamination Control Guidelines Chapter 4 – Problem Solving for Contamination Control

EXAMPLE:

To institutionalize the cratering fix, the resolution was documented and incorporated in
GM’s Bill of Process and Bill of Materials.

4.6 Communicate: Share Best Practices

Communicating success stories and lessons learned is key in allowing everyone to be

part of the problem solving achievements. This helps get all employees involved and
excited about the company’s continuous quality improvement efforts. Communication
encourages employees to become a part of that effort.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

CHAPTER 5 – CONTAMINATION CONTROL GUIDELINES,

PROCEDURES, AND BEST PRACTICES
GM prides itself on quality, right down to a flawless paint job on its vehicles. This
commitment to excellence requires strict standards for paint shop cleanliness and
control of incoming materials. Therefore, contamination control efforts must focus on
four key areas:

• Facilities
• People
• Material
• Processes

The following procedures, guidelines, and best practices address these areas and in
particular provide detail regarding:

• Paint shop construction and deep cleaning for first time use
• Apparel and work guidelines for paint shop personnel
• Contamination source control including indirect sources (incoming supplier
materials) and direct sources (GM paint, wipe cloths, etc.)
• Controlling contaminants generated in the paint process

These guidelines should be followed to ensure the cleanest possible environment for
the paint shop.

Appendices
Related Materials
Appendices include the following related materials:

• Appendix B: Facilities assessment for contamination control

• Appendix C: Common sources of contamination
• Appendix D: Contamination control procedures for paint shop start up following
an extended shut down
• Appendix E: Supplier forms
.

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PAINT SHOP CONSTRUCTION AND DEEP CLEANING

When new paint shops are built or when deep cleaning is required, most GM plants
contract with a supplier for the deep cleaning services. Occasionally you find a plant
that still performs the deep clean procedures themselves. This section includes a
checklist (summary) for deep cleaning a paint shop and related areas such as the mix
room. For additional information, see GM deep cleaning policy documents BP055A and
34955.

Job Aids

Use the following checklist as a job aid during plant deep cleaning.

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DEEP CLEAN CHECKLIST

Item (Page 1)
✔
Paint Shop Facilities Construction
Building Access
Protect building access during construction to prevent dust and dirt from
prevailing winds to enter and settle on clean equipment. Wash all vehicles prior
to entry and wash floors regularly.
Remove dunnage and shipping materials prior to installing at designated
staging areas. Remove all transportation dirt prior to actual installation.
Pre-cleaning
The manufacturer must pre-clean sections using lint-free rags for all interior
supply duct work and the interior of all air supply units.
Equipment
The Contractor furnishes all equipment, tools, and supplies necessary for the
cleaning work, including but not limited to scrapers, shovels, safety belts,
brooms, painter picks, scaffolding, man lifts, and sweepers.
Use lint-free cloths, rags and wipers for cleaning.
Silicone and silicone type containing materials are strictly forbidden.
The Contractor must adhere to all GM Safety and Lock Out Procedures.
Compressed air / blow off cleaning will not be allowed without written consent
to avoid contamination of other areas.
Deep Cleaning
General Guidelines
Cleaning methods may consist of any combination of hand wiping and tacking,
dry vacuuming, wet vacuuming, chemical cleaning, sweeping, mopping, power
scrubbing, solvent wiping, and pressure washing.
Use the outside/inside and top/down approach on open systems and systems
which have the normal ventilation shut down (Elpo tanks and paint ovens).
Protect finishes during the deep cleaning process.
Use new and use-specific cleaning materials.
Use biodegradable soap. Neutralize any cleaning material before it goes to the
process drain systems or sanitary sewers.
Acid based metal cleaners are not allowed.
Coordinate cleaning activities with equipment installation schedules and / or
production operations.
Cleaned surfaces must be free of streaks.

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✔ Item (Page 2)

Safety is the number one priority due to the work required, i.e. high bays and
confined spaces.
Correct any working condition which, in the judgment of the Safety Manager is
unsafe.
Materials
Deliver all cleaning products to the site in sealed containers bearing the
manufacture’s name and instructions for use.
Store all cleaning products in approved space.
Remove surplus materials, containers, equipment, and tools promptly when not
needed or not in use. Collect oily rags and waste daily. Deposit them into
tightly covered metal containers. Clean up and dispose of debris at the close of
each workday and upon completion in each area. Do not pour solvents and
caustic solutions onto the ground or into sewers.
Cleaning Areas
Clean floor plating thoroughly, taking care to avoid damage to any finish or
paint coating.
Take precautions to prevent damage to lighting panels/fixtures; all process
equipment (mechanical and electrical); gauges, process sensors, photocells,
fire protection devices; electrical, pneumatic and hydraulic systems; control
panels, etc.
Remove and clean filtration and framework.
Clean ductwork inside and out using an appropriate combination of wet and dry
techniques. Use lint-free rags for all interior supply duct work and the interior of
all air supply units. Vacuum and spot clean the exterior of all air supply houses
and associated ductwork. Vacuum and wet wipe exterior of all fans, bases,
flexible connections, dampers and ductwork. Remove all access and
maintenance openings to ensure complete cleaning of the duct work system,
including the cleaning of the most remote and inaccessible areas. Smaller
ductwork cross sections require deep cleaning, and may require the use of thin
and flexible individuals capable of working in these locations.
Exhaust ducts that do not require cleaning should be sealed to avoid
contamination and ensure that dirt is not drawn from ducts and contaminates
deep cleaned areas.
Deep clean beginning with the roof decking, down to the structural steel, walls,
ceilings, and floor. Maintain the floor daily during deep cleaning. At the end of
deep cleaning, power scrub the floor.

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✔ Item (Page 3)

Vacuum and tack wipe all dirt and dust from all beams, girders, trusses,
ladders, stairs, railings, guardrail, piping, ductwork, conduit and light fixtures
and cable trays to insure a completely dirt free surface via whatever method is
needed. Examples are vacuuming, tack wiping and/or damp wiping.

Vacuum and tack wipe all dirt and debris, scrub floor, remove any overspray,
black marks, etc. Manually sweep aisles. Pressure wash walls and aisles
where accessible. Pressure wash walls, ceiling and floors of the grade level
ductwork.
Damp, wipe and dry to prevent streaking from the top chord down. Remove dirt
and dust from wall panels via scrubbing and pressure rinsing.
Coordinate all cleaning of the various Phosphate components in advance of
the actual work. All work will be coordinated with plant tank cleaning
operations. All cleaning shall be performed with de-ionized water.
Upon completion of cleaning operations in the post-Phosphate inspection deck,
proceed into the Elpo Pre-Wet Spray enclosure. This area requires general
cleaning (vac and tack). No cleaning is required inside panels. Cleaning of
paint residue on paint cabinets, grating and under grating is required.
After lock-out of the conveyor system, tack wipe, solvent wipe (if necessary)
and vacuum debris from all components of the conveyor system including
track, chain, yokes, hangers and structural members.
After lock-out and safety procedures, perform a general cleaning of the interior
sheet metal, lighting, conduit, piping, grating, floodpan and water nozzles. Tack
wipe and vacuum all interior surfaces. Solvent wiping may be required on
residual paint accumulations.
The entire interior and exterior surfaces of the plastic clean tunnels must be
tack wiped and vacuumed of dirt and debris.
Clean the inside of spray booths, enclosures, tunnels, clean room enclosures,
etc., including, silhouettes, doors and windows. Clean stainless steel surfaces
with lint-free rags and suitable stainless steel cleaner (no streaks permitted).
Deep clean the exterior of booths / enclosures from the top of the plenum to
the floor supporting the scrubber or tank section. Deep clean the exterior booth
walls, scrubber / tank exterior walls, etc.

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✔ Item (Page 4)

Vacuum, wipe and tack clean all interior surfaces of the plenum. Open, clean
and seal all maintenance and access openings after deep cleaning. This
includes filter ceiling and frames, perforated plates, piping and supply duct
inlets. Seat filter media after the deep clean process. Pay special attention to
filter media hold down devices and the screen mesh material that supports
distribution media.
Using the proper safety lanyards, ladders, etc., hand wipe entire booth walls,
glass and doors.
Remove all dust, residual paint, sludge, stains, etc. to bare metal.
Using the top to bottom method, remove all accumulated dirt or loose paint
from sheet metal surfaces, including ceilings, walls, ductwork plenums,
nozzles, etc. to the cleaning plan acceptance level.

The clean room is a critical part of the owners process operations. Take
precautions to insure alignment with the cleaning plan.
The clean room will be cleaned last during the cleaning process.
Clean the clean room ventilation system supply and return duct work,
mechanical cooling systems, filtration, diffusers, supply fans, recirculation fans,
etc.
Pressure wash the interior of all air supply units.
Vacuum and clean the interior and exterior of all air supply houses and
associated ductwork. Vacuum and wet wipe exterior of all fans, bases, flexible
connections, dampers and ductwork.
Thoroughly clean the supply / recirculation fans inside and out using a
combination of wet and dry cleaning techniques. Use lint-free rags where
manual wiping is required. Vacuum and wet wipe exterior of all fans, bases,
flexible connections, fan guards, dampers and ductwork. Open all maintenance
hatches and access opening for deep cleaning of remote areas. Clean the fan
blades, interior fan housing, control vanes, protective coverings etc. Remove
excess grease on bearings etc. with the appropriate grease removing material.
Chemical wipe, tack wipe and vacuum benches, tables, lenses, ventilation
ducts, discharge grilles, exhaust grilles, piping conduits, and bottom chord of
truss.
Remove all dust and dirt from conveyor equipment, transfers, lift tables,
pumps, piping, etc. Remove all guards from floor mounted conveyors and
clean the floor below the conveyor. Replace guards when complete.
Clean all conveyor guards, drip pans and carriers.

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Paint Shop Contamination Control Guidelines Procedures, And Best Practices

✔ Item (Page 5)

Hand clean conveyor carriers using damp clean or tack rag methods. Pay
attention to bottom carrier rail and wheels.
Use the oven manufacturer recommended cleaning procedures. (Please
reference site specific drawing and specification for possible exceptions.)
Power cleaning may be used as one of the cleaning steps. Dry clean the oven
to remove large debris prior to any power washing. Take care during interior
cleaning, as sensors, components, etc. are sometimes not discernible in the
oven lighting.
Inspect, remove, store, re-install, re-inspect and properly seat heater and oven
filters after deep cleaning.
Clean the ovens, cooling tunnels, under platform enclosures, and heaters
inside, including return ducts, supply ducts, plenums, fans, fans blades, cones
and baffle plates, dampers, burner plates, etc.
Once safety tie-offs and secured ladders etc. have been established, vacuum
and tack wipe all ceiling elevation building steel, piping, ventilation ductwork,
lighting and conduits.
Using a two step, top down method, wet mop all wall and floor surfaces, once
all control panels, junction boxes, pull stations, etc. have been covered with
plastic sheeting.
Any necessary combination of dry clean methods, vacuuming, solvent wiping,
etc. is acceptable for the cleaning of the powder paint components.
Wet clean methods will not be used. The standards for cleanliness described in
this specification will apply to all powder systems.
Any necessary combination of dry clean methods, vacuuming, solvent wiping,
etc. is acceptable for the cleaning of the powder paint components. Wet clean
methods will not be used. The standards for cleanliness described in this
specification will apply to all powder systems.
The powder equipment supplier will be required to provide a detailed deep
cleaning procedure.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

PAINT SHOP PERSONNEL

CLEAN ROOM PRACTICES

BASIC PHILOSOPHY

Statistical data from a number of plants points to fiber contamination in at least 50% of
the repair repaints. Most of those fibers come from people, cloths, and miscellaneous
maintenance and various cleaning operations. These free floating contaminants are
usually transmitted to a vehicle through direct contact. Fibers represent random
potential problems that must be controlled. To stabilize the process and reduce this
background, a clean room is a basic requirement.

Three Results of Establishing Clean Room Rules

Clean room rules are vital and result in the following:

• A clean room removes common causes of contamination directly contributed by

operating personnel. These include clothing, newspapers, food, drinking containers,
miscellaneous containerization, etc
• Secondary effect of persistent cleanliness controls is that a limited number of outside
personnel will enter a paint shop. This is a direct result of requiring special paint
shop wear and having restrictive clean room practices such as no eating, drinking,
etc. This additional element further reduces contamination
• The third effect of clean room rules is that the type of activities conducted in the
paint shop are limited and controlled. Maintenance and construction are conducted
elsewhere if at all possible. If it is necessary that these operations be conducted
within the paint shop, they will be carried out with special controls such as plastic
surrounding them.

Adherence to these basic philosophies will result in a reduction of “common” causes

and subsequently reduces variability in the process.

Note: Some support personnel do not follow clean room procedures as prescribed. This
is based on the belief that vehicles are cleaned prior to paint anyway. This belief fails to
address the plethora of other secondary sources of fiber and dust such as body interior,
cowls, under hood areas, etc. during the spraying process.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

PHYSICAL CLEAN ROOM

Paint shops should maintain the entire paint shop as a clean room and maintain
physical access restrictions. Background dust and fibers are significantly reduced
through the removal of the sources.

Reduction of general access and mandatory wear of lint-free coveralls, gloves, and hats
can have significant benefits. The addition of blow-off chambers, physical enclosures,
and enhanced ventilation will add additional controls to reduce fiber populations from
personnel, as well as reinforce the psychological aspect of the entire paint shop as a
special manufacturing environment.

The provision of an enclosure or inner clean room around the prime and topcoat booth
adds a further layer of isolation around the prepared vehicle. Most importantly, it further
maintains cleanliness and control of hand sprayers and protects maintenance personnel
that operate in the actual spraying environment.

From a ventilation and air movement viewpoint, these physical elements of a clean
room can never eliminate airborne dirt if clean room practices are not followed. The
problem can be isolated through the control of people’s clothing and miscellaneous
items which are the most common contributors of dirt in the paint.

A continuing program of lint source reduction must implement the use of approved
indirect materials. This includes wipers, tack cloths, presaturated wipers, robot covers,
and coveralls.*

BEST PRACTICES

Overall Paint Shop Environment

• The entire paint shop should have restricted access

• Approved coveralls must be worn by all personnel in all areas of the paint shop
• Educate paint personnel as to why wearing approved coveralls is essential
• The flow of non-essential personnel should be directed around the outside of the
paint shop
• Only essential vehicles should be allowed in paint shop
• Essential vehicles should be confined to paint shop so outside mud and dirt do not
get into paint shop
• Generally, street clothes contribute twenty times the lint to the surrounding
environment compared to properly laundered clean room wear

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• Do not allow eating, drinking, or smoking anywhere in paint shop other than
designated areas which should be totally enclosed and away from process areas
• Containers and by-products from eating and drinking have direct effect when they
are being used near the product, as well as the indirect effect if carried into ovens
with the product where heat deterioration will decompose them
• Decomposition of these products will add fibers and ash to the oven environment
Consumable products such as paper and tape should be thoroughly investigated
prior to use to determine their fiber generation capability

*Extensive analysis of paint contamination in GM paint shops shows that as much as 50% is due to
fibers. Microscopic identification reveals these fibers to come from clothing, indirect materials, (wipers,
tack clothes, gloves, etc.), filters, and paper/cardboard/wood products. Defects resulting from these fibers
require extensive rework in order to maintain a high quality paint finish. We are taking steps to reduce
these fibers through an extensive program to test, evaluate, and control all materials coming into the paint
shop. Our overall objective is to improve paint quality for General Motors customers.

The implementation of the BMNA Paint Shop Indirect material Approval Process for wipers, tack cloths,
gloves, and robot covers, requires suppliers to meet rigorous fiber elimination requirements before they
are able to submit their products for testing and approval. Paper/cardboard/wood and other fiber
containing packing materials have also been identified as a source of paint defects. Therefore, this
process includes the requirement that suppliers must eliminate any pariticulate-causing packaging
materials from their products as delivered. The supplier must take steps to provide and originate this fiber-
free packaging at their initial shipping point.

This fiber-free containerization policy is further directed to all suppliers, commodity managers and
integrated suppliers providing any type of production or indirect material to our paint shops, or to a stores
area for use in the paint shop. Suppliers of strip, patch, and thumbgrade sealers, body plugs, add-on
parts, and any other products coming into the paint shop all must adhere to the Paint Engineering
Contamination Control Policy requiring fiber–free packaging. This requirement also applies to any pallet
used to ship or transport these products into the paint shop.

Therefore, our policy required all suppliers providing materials to paint shops to ship these products in
fiber free packaging, or have a detailed plan to implement this fiber free requirement by the end of 1999.

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Clean Room Wear

The paint shop is not the proper place to make a fashion statement. Coveralls and head
gear worn in the paint shop commonly referred to as “approved coveralls and hats”
though drab, are a vital part of a comprehensive program and worn in all parts of the
paint shop. Please leave your fashion sense in the locker room and stick to the
contaminant free clothing.

Coveralls must be received in “fiber free” packaging and must be laundered three times
prior to first use. Coverall change frequency must be operation specific with personnel
such as sprayers having higher change frequencies. Actual change frequency must be
established locally and will vary with paint materials used and operation location.

An integral part of the process is the cleaning and packaging of the laundered coveralls
and hats. The laundry must be capable of removing most paint accumulation from the
coveralls.

In addition, all clean room wear must be laundered in a segregated area in dedicated
washing machines and dedicated low temperature dryers. The area where washing and
drying, repair, and packaging take place must be segregated with smooth walls and
ceilings. Positive ventilation in relation to the surrounding area, filtration equal to 50%
ASHRAE dust spot efficiency, and a minimum relative humidity of 50% year round.
Packaging and repair must take place within the clean room and all personnel must be
fully clothed in clean room wear. An active crater awareness program must also be
adhered to for the best overall results in achieving an effective clean room environment.

Job Aids

Use the following checklist as a job aid for clean room policy.

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Clean Building Policy

GM has established the following clean room policies:

✔ POLICY EXPLANATION

1. Specified lint-free full In some studies, over 60% of paint defects were
coveralls will be worn in traced back to the people in the vicinity of the
all areas. paint shop. For this reason all people in this
paint shop are required to wear lint-free, no-
static, full coveralls. These are a new corporate
specified design by Safety Centers Inc.

2. Coveralls will not be To keep coveralls clean and in an environment

worn outside the clean that is controlled with respect to paint
building. The only contaminants, coveralls will not be worn outside
exception is to and from of the clean building. The one compromise to
lunch. this is travel to and from lunch due to time
constraints. We do however ask that whenever
possible coveralls be removed before leaving
the clean building for lunch.

3. Coveralls cannot be The purpose of coveralls is to trap any fibers or

altered and must be other contaminants on the person and hold them
worn with zipper full up, in. If sleeves or neck are left open, coveralls
sleeves down, and all become much less effective and act like a
snaps snapped. bellows pumping these particles onto the
vehicle. To be fully effective coveralls must be
zipped full up to the neck, snapped at the
sleeves and legs, and never cut open or
shortened.

4. At no time will coveralls Coveralls are cleaned by a specified laundering

be allowed to be washed and packaging process to avoid contamination
at home. from lint, fibers, or chemicals. If coveralls are
washed at home they are no longer in a
controlled environment and may be
contaminated by otherwise harmless household
chemicals, cotton fibers, or other particles that
could cause paint defects.

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✔ POLICY EXPLANATION

5. No one is allowed in Another way to maintain cleanliness in an area

booths, powder rooms, is to restrict access and control traffic that is
or mixroom without allowed. Only those people who have work in
specific authorization. the topcoat, powder, and mixroom areas will be
allowed free access.

6. No one is allowed into Similar to number (5) above, anyone other than
the paint facility without the people who work in the paint building will be
specific written required to have written authorization for
authorization. entrance into the paint building.

7. All doors must remain The booths, clean rooms, and the entire building
closed for all booths, are pressure balanced to control the dirt that
clean rooms, and could pass from one area to another. This
outside walls. necessitates that all booth, clean room, and
building doors be kept closed at all times.
Exterior doors are particularly important to keep
dirt outside.

8. Air showers are the only Air showers provide an air lock effect to isolate
entrance into clean the clean room environment and also blow off
rooms. and capture any lose contaminants on coveralls.
These air showers are the only way to enter or
exit the clean rooms in the case of an
emergency.

9. In the powder booths, To enter the powder clean room, hair nets and
coveralls, hair nets over special shoe covers must be worn. Hair nets
the ears and specified trap and hold hair and other particles on the
lint-free shoe covers are head. They must be worn down over the ears
required. and cover all head hair to be effective. Special
shoe covers are also required to keep material
from shoe bottoms out of the hoppers below the
booth grating.

10. In the topcoat booths, Similar to the powder booth above, hair nets are
coveralls, hair nets over required in the topcoat clean room. However,
the ears, and rubber rubber shoe covers are required only inside the
shoe covers are booth to keep from tracking paint out into the
required. aisles.

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✔ POLICY EXPLANATION

11. No eating, drinking, or Eating, drinking, smoking, newspapers, books,

smoking in the clean and magazines will be restricted to these areas
building with the to keep the contaminants associated with these
exception of break away from the vehicles and to help maintain the
areas, locker rooms, clean environment in the rest of the clean
restrooms, and cafeteria. building. The office area and the restrooms in
the office area will have these same restrictions
with the exception of papers and books needed
for normal operations.

12. No newspapers, See number (11) above.

magazines, or books in
the clean building with
the exception of break
areas, locker rooms,
restrooms, and cafeteria.

13. Cardboard, wood, lint or All paper and wood products produce particles.
particle producing Newspaper being one of the worst offenders.
materials will not be Every effort will be made to keep these products
allowed in clean building out of the paint building. One of the ways this is
areas whenever done is through the cooperation of outside
practical. suppliers in using plastic packaging rather than
cardboard.

14. No unit can be touched Due to the new waterborne and powder
without approved lint- technologies, it has never been more important
free gloves. to not touch vehicles with bare hands that can
leave oils and other contaminants. This
awareness must extend beyond people who
routinely touch jobs to those who may only
occasionally work in the vicinity of vehicles.

15. The above listing is not This must remain a “living” document that can
all-inclusive and may be be updated as the need arises to keep the high
altered as necessary to quality standards we have set for ourselves to
insure a high quality, produce a “world class,” defect free, paint finish.
world class vehicle.

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INDIRECT MATERIALS TESTING AND APPROVAL

INDIRECT MATERIALS APPROVAL

GM has established the following process for Paint Shop Indirect Materials Approval:

• Initial screening of the product and supplier

• Lab testing of product(s) to meet material and performance specifications
• Plant validation of product performance
• Assessment of process capability and quality control
• Quotation process by worldwide purchasing
• Purchase order and common code issued

The initial step in the process is the high-level screening of the supplier for the following
requirements:

• All paint shop indirect materials suppliers were required to be ISO 9000 Certified by
1999
• Eliminate all fiber- and particulate-causing packaging materials from the plant paint
shops
• Reduce the number of interim manufacturing, converting, and distribution suppliers
for each product to maintain the tightest control over the manufacturing and quality
control processes

Suppliers must complete a Supplier Information form, Product Information form, and
Supplier Acknowledgment form to be considered.

Before a supplier product is approved, he/she must submit a Test Request Form (TRF)
for each product to be used. The supplier receives a copy of all the test results. A copy
of all the tests to be performed, according to the type of product, is included with this
material.

See the Test Request Flowchart on the following page.

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TEST REQUEST FLOW CHART

NOTIFICATION TO SELECTED SUPPLIER

(PAINT ENGINEERING)

TEST REQUEST FORM (TRF)

(PAINT ENGINEERING)

TEST LAB REQUIREMENTS TO SUPPLIER

• COMPLETED & APPROVED TRF
• COST QUOTATION
• TIME SCHEDULE
• SAMPLE INSTRUCTIONS/QUANTITIES

SUPPLIER RESPONSES TO TEST LAB

• PURCHASE ORDER
• SAMPLE(S)
• MSDS/PRODUCT SHEETS

TEST LAB CONFIRMATION TO PAINT ENGINEERING

TEST LAB INITIATES TESTING

PAINT ENGINEERING SPECIFICATIONS

TEST LAB INVOICE TO SUPPLIER

SUPPLIER PAYMENT TO TEST LAB

TEST LAB TEST REPORT TO SUPPLIER/ PAINT ENGINEERING

TEST DATA INCORPORATED INTO MATERIAL TESTING DATABASE

(TEST LAB)

APPROVED (PAINT ENGINEERING)

• PLANT TRIALS
• SUPPLIER ACTION

REJECTED (PAINT ENGINEERING)

• SUPPLIER ACTION

Once the supplier’s product meets the technical requirements according to the lab tests,
the supplier then provides samples to the designated plants for the plant validation
process.

If a supplier is to be approved, Worldwide Purchasing assesses the product costs and

issues a Purchase Order and Common Code(s).*

A flowchart of these supplier approval steps appears on the following page.

*For a listing of approved indirect materials, go to GM online, or ask any Paint

Engineering Contamination Control Team member.

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Paint Engineering
Indirect Materials Approval Process
Flow Chart

1 4 8 10 12
Approval Test Request Form Plant Validation Process Capability GMNA Paint
Request by to Supplier Performed On-Line & Quality Control Approval
Supplier by Dirt Team Measures Assessed

11
2 5 9 13
Meets Process
Product & Supplier Material Submitted Meets Production Quotation Process
Capability and
Screening by to Lab for Testing Application by WWP
No No Control & Quality
GMNA Paint & WWP by Supplier Requirements Standards

Yes Yes

14
3 6 Meets
Meets Lab Tests Products Product/Process
Requirements to GMNA Paint Economic
No No
Specifications Feasibility

Yes Yes

7
Meets Technical
No Requirements per
Specifications

Yes 16 15
End Purchase Order
Approval Process & Common Code
Issued

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MATERIAL QUALITY CHECKS

DIRECT MATERIALS

PAINT TESTING AND CLEANING

Paint testing must provide quantitative as well as qualitative results of paint cleanliness
and an identification of the contaminants found. The procedure specified by GM is used
to quantify paint cleanliness at the following locations.

1. Incoming containers - totes, drums as delivered for use at the paint shop location
2. Circulation system tank
3. Main line application spray booth

Equipment

• Sample Collection Kit

⇒ Graduated collection device (sufficient for 500 ml )

⇒ Millipore Trogamid Paint Monitors
-appropriate micron mesh size to paint type
-see attached bulletin for part numbers
⇒ Luer fitting adapter (Area 2, 3 testing )
⇒ Millipore Tubing Pump ( Area 1 testing )
-Millipore P/N
⇒ Tubing Apparatus (Area 1 testing )
⇒ Sampling Cart
⇒ Male Luer X Quick Disconnect fitting
⇒ Tote vent cap (bung) wrench

• Lab Monitor Rinsing/Evaluation Kit

⇒ Tubing ( 1 piece approximately 2 feet in length )

-Waterbase Masterflex
-Solventbase Masterflex
⇒ Forceps
⇒ Filtered rinse or reducing solvent
⇒ Stereo microscope with eyepiece cross-hair insert, light source, and appropriate
background

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Selection of Paint Monitors

Selection of the particular micron rating to be used on individual paint types shall be
based on the average particle size in the coating material. Final evaluation
membrane size shall be determined by both the user plant and the paint supplier.

Once a size is designated, tests shall be conducted at the designated size as well as
the next lower size if defect levels dictate further examination. Subsequent decisions
shall favor the lowest size.

Monitor
Paint Type Size Part# (microns)

Clearcoat 25 M025N3750
Primers 25 M025N3750
Anti-chip primers 50 M050N3750
Metallic basecoats 75 M075N3750
High enhancement colors 125 M125N3750
e.g. Micas, Pearls
Solvent (for rinsing) 10 M010N3750

Sampling Procedure

A 240 ml representative paint sample passes through a Millipore Paint Monitor via the
specified pump or via gravity. The Monitor is then rinsed to remove residual paint to
provide a “clean” background from which to visually count dirt and fiber particles and
ultimately assess paint cleanliness. Particles are identified by type and recorded as
such in order to identify sources of contamination. The particle counts are also totaled to
give a meaningful total count rating to the individual sample. The initial total count (A) is
made and then divided by two (A/2). This result (A/2) is then subtracted from ten to yield
the final cleanliness result.

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Sample Collection Procedure

Area 1- Incoming Totes

1. Collect together all four major items, the wrench, the pump, the tube assemblies with
the correct number and micron sizes of monitors to be used. Proceed to the gravity
feed rack.

Note: The totes that are placed upon the gravity feed rack in the paint dock should
be agitated for approx. 1 hour. Agitation should be underway prior to collecting the
apparatus for the sampling procedure.

2. Mark the monitor to be used with batch, tote, date, and micron rating of monitor.
3. Set all equipment down on top of the tote or drum.
4. Remove blue (inlet) and red (outlet) caps from appropriate monitor, placing monitor
on tote top so this outlet is facing up.
5. Install the tubing assembly (four feet) with Luer connector into pump and attach Luer
connector into outlet of Monitor. (Familiarity with the operation of the peristaltic pump
is essential when threading the tubing through the cam housing. The pump rotates
clockwise, therefore wrap the tubing starting from the left side, around the cam lobes
clockwise. Allow one foot of tubing from outlet of cam set to the monitor inlet to
provide enough slack to position in the pump comfortably. Clamp the cam housing
slit sections together, and secure retainer on the tube.)
6. Open the vent cap (bung) of the tote with the appropriate wrench.
7. Install the tube assembly to the flange of the vent opening so that the tubing is
submerged approximately 6” into paint.
8. Before installing monitor to the Luer connector, the tubing must be flushed to ensure
no extraneous contamination is measured. Connect the pump to an air supply line,
turn the pump on, and run approximately 100 ml of paint through tubing and stop.
This will effectively eliminate any residual contamination present in the tubing.
9. Install Monitor by pressing Luer male connector into the inlet of the Monitor. While
holding the Monitor above the graduated container, start pump and run until an
additional 240 ml of paint has been collected then stop pump.
10. Remove Monitor from Luer connectors and recap using red and blue caps and set
aside.
11. Dispose of tubing assembly, empty graduated container and move on to next tote or
drum.
12. Repeat procedure on the required number of totes then return Monitors to the Lab
for flushing and evaluation.

Note: The procedures outlined in 3.4.1 should also be conducted before the
container leaves the supplier’s facility.

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Area 2 - Mix Room

1. Assemble all pieces as done for the test on incoming totes and place on top of
sampling cart.
2. Position cart in front of system tank.
3. Install air line to pump system and repeat procedures 2 through 12 of Tote Sampling
procedure.

Area 3 - Spray Booth

This test can be done in two ways; procedure A involves the use of manual gun line
drops, procedure B uses a gun retainer to connect the monitor directly to automated
application systems (Gun suppliers should be able to supply individual plant locations
with these adapters).

Procedure A - Using Manual Gun Line Drops

1. Assemble the pieces required for this test on the sampling cart.
• Appropriate Monitors
• Luer X Quick Disconnect fitting
• Graduated container.
2. Remove line drop from gun line.
3. Position cart below line drop.
4. Isolate drop from main pressure line by closing upstream valve.
5. Attach Luer X Quick Disconnect fitting.
6. Hold graduated container below Luer fitting and carefully open isolating valve to
allow for flow.
7. Collect 100 ml in the graduated container to allow for rinsing of the fittings and line,
then close isolation valve.
8. Remove inlet (blue) and exit (red) cap from appropriate Monitor.
9. Install Monitor to the Male Luer fitting.
10. Hold graduated container below the monitor and carefully open isolation valve to
allow for flow.
11. Collect an additional 240 ml of paint in graduated container and close valve.
12. Replace the caps on the Monitor, remove quick disconnect, and store in solvent.
13. Repeat procedure on all other lines.

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Procedure B - Using the Paint Monitor Gun Retainer

1. Remove the air cap on the applicator, making sure to follow appropriate lockout
procedures as required for automated systems.
2. An appropriately sized O-ring should be attached to the end of the nozzle to provide
a seal between the monitor and the nozzle (monitor orifice attributes - 0.156” ID,
0.357” OD).
3. Place the monitor inside of the monitor retainer and fasten the assembly onto the
gun body. Do not over-tighten, but secure well enough to provide an adequate seal.
4. Select low flow on the controller for the applicator and pass 240 ml of paint through
the monitor.
5. Replace the caps on the Monitor, and store in solvent.

Rinsing Procedure

Blank Run

In order to determine background contamination, on a monthly basis perform the

following rinse steps on a clean Paint Monitor without paint. The levels of contaminants
should be logged to determine background contamination counts and procedures to
filter rinse solvent should be modified accordingly.

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Monitor Rinse

1. Connect the tubing pump to an air supply and wrap masterflex tubing through the
pump head.
2. Insert Luer connector to the end of the masterflex tubing.
3. Remove outlet cap (red) from the Monitor and connect it to the Luer connector on
the masterflex tubing.
4. Remove the inlet (blue) cap from the Monitor, turn on the tubing pump, and squeeze
filtered solvent from squeeze bottle into the monitor. This effectively draws solvent
through the monitor removing residual paint solids. Using forceps, insert blunt end
into the top seam on the side of the Monitor and twist the forceps to separate the top
from the body of the Monitor.
5. If additional rinsing is required, turn the vacuum pump on and hold Monitor top
against side of monitor, squeeze filtered solvent from squeeze bottle against the top
section to clean, while letting solvent flow into bottom section. Rinse all exposed
areas including nylon mesh and walls of Monitor as vacuum is applied. Continue to
rinse until all residual paint is flushed from the mesh and walls.
6. Once Monitor is free from paint debris, replace Monitor top section and then turn off
vacuum. The sample is now ready for microscopic analysis and subsequent
evaluation.

Evaluation

Blank Run

The overall cleanliness of the environment is evaluated by counting and categorizing

the particulate contamination left on the Monitor used during the blank run. This will
provide background or baseline particle counts of the evaluation of Monitor samples
taken from totes and the circulating paint system. In order to proceed to Monitor sample
evaluation, the value determined from the blank run should be less than 5% of the
lowest maximum value on the control plan for the paint products tested at that site.

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Particle Identification

The count results should be plotted for each color and paint line at the different sample
points.

1. Mica (Oversized)
2. Aluminum (Oversized)
3. Synthetic Fiber
4. Cotton Fiber
5. Cellulose Fiber
6. Resin Seed
7. Pigment (Oversized)
8. Dried Paint
9. Paper
10. Other

Contaminant Category Description

Listed below are descriptions of the particle categories in 4.2.0 which will be helpful
when initially identifying contaminants.
Mica - flat, sometimes translucent flakes that refract light making the flake color change,
very sharp edges.
Aluminum - flat metal flakes; most have smooth rounded edges, very reflective.
Synthetic Fiber - smooth, round, very regular fibers; may have a characteristic loop or
weave pattern, usually clear but may be colored.
Cotton Fiber - flat, twisted, very irregular fibers; may be colored.
Cellulose Fiber - similar to cotton; larger fibers may have cellular flakes.
Resin Seed - translucent to clear particles, usually shiny, color varies from clear, white
to amber.
Pigment - irregularly shaped particle, color varies with type of pigment may be different
color than paint.
Dried Paint - flat flake of irregular shapes, may see different layers and colors.
Paper - similar to cotton, some larger fibers may have cellular flakes.

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Appendices
Related Materials
Appendices include the following related materials:

• Appendix G: Photographic examples of contaminants, and results thereof

Evaluation Guidelines

1. Large agglomerations of particles, which can’t be counted individually, are cause for
immediate rejection.
2. Indistinguishable agglomerates are cause for immediate rejection.
3. The monitor sample is placed under the magnification necessary to identify and
count all particles on the screen.
4. Sum the particles in each category.
5. Shift the monitor sample under the microscope to allow for viewing all areas of the
screen.
6. The particles are individually identified and recorded as well as a total rating given to
the test sample.

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7. The figure below shows, graphically, the sizes of particulate that will inevitably cause
appearance problems. Any particulate in the ranges identified should be noted as an
alarm.

>50 µ

>50 µ

>50 µ

>15 µ

>250 µ

>15 µ

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PHOSPHATE TESTING

GM has developed a method for identifying the proper procedure for collection,
categorization, and evaluation of particulate contamination in liquid samples of
phosphate system process solution. This “Millipore” test can be implemented in several
ways within the phosphate system:

• Tank contamination levels

• Filtration performance

EQUIPMENT

Sample Collection: Millipore Portable Paint Test Kit

• Millipore Tubing Pump

• A 3 foot and 5 foot length of Masterflex tubing
• A 3 foot length of (0.25” OD) copper tubing
• Collection container with 3 liter capacity
• Luer fittings
• Millipore Trogamid 10 micron Paint Monitor
• Sampling container
• Compressed air supply

Lab Analysis

• Stereo Microscope (particularly one with eyepiece cross hair insert) and light source
• Scale capable of measuring tenths of a milligram
• Laboratory oven capable of 150°F

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SAMPLING PROCEDURE

Tank Samples

1. Connect the Millipore pump to an air source at the test location.

2. Select a 10 micron Trogamid Paint Monitor and remove caps from the inlet and
outlet of the monitor. Save the caps for future use. Place monitor in pump retaining
clamp.
3. Thread three-foot length of Masterflex tubing through pump and connect with luer
connector to bottom of paint monitor. From the pump, the tubing should be clamped
to the collection container.
4. Connect five-foot Masterflex tubing to top of paint monitor with a luer connector and
attach loose end of Masterflex tubing to coper tubing.
5. Insert copper tubing desired depth into tank to be tested.
6. Turn on pump. Draw the 3 liters through the monitor into the collection vessel. Turn
off pump.
7. Remove tubing attached to top of monitor. Briefly turn on pump to remove the
residual solution.
8. Replace inlet and outlet caps on monitor.
9. Label monitor with marker. Include sample location, depth, and number.

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Filtration Performance

1. Install a pressure gage and sampling valve on the inlet and outlet side of the filter
vessels. The sampling valve should have a ¼” tubing adapter installed with a four-
foot length of Masterflex tubing attached.
2. Connect the Masterflex tubing to a Trogamid 10 micron Paint Monitor with a luer
connector.
3. Hold the monitor over the collection container and open the sampling valve allowing
process solution to flow through the monitor and into the collection container.
4. Collect a three-liter sample of process solution, then close the valve and put caps
back onto the Millipore Paint Monitor.

Note: If the monitor becomes plugged, then close the valve, get another monitor and
continue until a three liter sample is obtained.

5. Repeat steps 1 through 4 for the outlet side of filter vessel.

6. To remove residual process solution, connect the tubing pump to an air supply.
7. Thread three-foot length of Masterflex tubing through pump and connect with a luer
connector to bottom of paint monitor. Allow the end of the tubing to empty to drain.

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TEST SEQUENCE FOR INDIRECT MATERIAL TESTING

LABORATORY TEST SERIES REQUIREMENTS

Bi-Directional Shake Test

This test method is used to evaluate the number of particles that are released by a
material that has been placed under mechanical stress in a liquid environment:

• A two-liter container is filled with DI water.

• A background count of the water is determined before the sample is added.
• A sample is placed in the container, sealed and agitated using a wrist-action shaker.
• After agitation, the concentration of particles released (within the 3-400 mm diameter
range) is determined.

Readily Releasable Test

This test method is used to evaluate the number of particles that are readily releasable
from a material without the application of mechanical energy in a liquid environment. A
glass pan is filled with de-ionized (DI) water. A background count of the water is
determined before the sample is added. The pan is gently agitated and the number of
particles released (within the 3-400 mm diameter range) is determined.

Haden Tube Test

This test measures the number of particles released by a sample’s edges when the
edges are under stress. Two samples from the same package are folded to expose the
sample’s edges. The edges are secured using clamps and the edges from each sample
are rubbed together over a tacky surface. The number of particles released are then
counted.

Absorbency Capacity

This test is used to evaluate the volume absorbed per unit mass and per unit area of
clean room wipes. A sample is cut into a trapezoid and weighed using an analytical
balance. The sample is immersed in solvent and then allowed to hang dry for a
specified time. The sample is re-weighed to determine the sample’s absorbency
capacity.

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Uniform Solvent Distribution

This test determines the uniformity of solvent contained in individual pre-saturated

wipes per package: Four wipes are taken from one package of samples at specific
locations. Each sample is weighed and then placed in an oven to dry at a specified
temperature and time. Each sample is re-weighed after baking and the amount of
solvent in each wipe is determined.

Wiping Efficiency

This test determines the amount of contaminant removed from a panel by a

pre-saturated wipe: Six panels are numbered and weighed. Five panels are coated with
a specified amount of contaminant, and re-weighed. The six panels are positioned in
order, with the uncontaminated panel last, and a sample is placed on the first panel. A
weight is placed on top of the sample and the sample is pulled across the panels using
a wiping machine. The panels are then weighed again to determine the amount of the
contaminant was removed. The test is performed under known amount of contaminant,
pressure, distance, and speed of wiping.

Snag Test

This test is used to determine the snagging resistance of a sample and decide the
potential generation of fibers caused by the snag: A sample is wiped three times against
a board impregnated with tacks. The wipe is evaluated based on three categories: rips,
distortions (imperfections at surface level), and protrusions (imperfections above
surface level). A total score is determined based on cumulative results using the
following weightings: each rip multiplied by 10, each protrusion multiplied by 5, and
each distortion multiplied by 1.

Tack Transfer Test

This test will evaluate the amount of tackifier that is transferred during a wiping
application. Two pre-weighed panels are placed together in a receptacle. A weight is
applied to the wipe and the wipe is moved across the panel at 12 in/10s. This is
repeated 5 times and the panels are re-weighed. The amount of tackifier deposited on
the panel is determined.

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Dirt Holding Capacity

This test determines the weight of contaminate retained in a sample: A metal pan is
filled to the desired amount of sanding dust and weighed. A sample is cut to a specified
size and placed flat on the sanding dust. A weight with the same dimensions as the
sample is placed on top of the sample for a specific time. The weight and sample is then
removed and the pan containing the sanding dust is re-weighed. This procedure is
repeated using a sample that had been exposed to the environment for six hours.

Telegraphing

This test is used to determine if a sample or released particles from the sample will
discolor or mar the paint. A sample is wiped across a 12’ x 12’ panel 3 times, a constant
rate motor is used to move the weighted wipe. The panel is then painted to a specified
mil thickness using an automated paint spray machine. Finally, the panel is evaluated
using a score of 1 for no telegraphing, 5 for slight to moderate telegraphing, and 10 for
severe telegraphing.

GM Wipemark

This is a test to determine if a sample will discolor or mar a test panel. A wipe is
saturated with a specified solvent. Utilizing a solvent rinsed 250 ml syringe, draw up
100 ml of the solvent from the wipe from its container. Dispense 100 ml on to the panel.
Three drops per panel should be applied. The solvent is allowed to evaporate after
which the panel is painted with automated equipment. Evaluation of the degree of
discoloration and paint effects is done for two wipes from the same package where: 1
equals no discoloration or defects, 2 equals minor defects, 3 for more visible defects
and discoloration, with total paint coverage, 4 equals more visible defects with slight
paint loss, and 5 for defects that show a large loss of paint.

GM Stove Pipe

This procedure requires the preparation of two 4” x 6” panels. The stock panels will be
E-coated by the manufacturer. Place a panel in the panel holder. Utilizing a draw-down
bar, apply a 3 mil layer clearcoat to the panel. Place 4” OD, 8” long PVC cylinder on the
panel with the clearcoat applied to it. Rotate the cylinder on the panel in a fashion that
will cause the cylinder to leave an impression in the clearcoat. Randomly select a
product and concentrating on the edges of the product rub the product over the cylinder
for thirty seconds. The panel is baked and evaluated for craters and number of particles.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

PROCESS CHECK

WELD BALLS
Metal spheres, ranging in size from 5 microns to several hundred microns, are formed
and released during metal joining and grinding processes. Paint Engineering has
established guidelines to control unattached weld balls in the cleaning stages of the
phosphate system and to continue control in the second half of the phosphate system.
Controlling metal in the cleaning stages is instrumental in the prevention of Elpo
contamination. If metal control is carried out before electrocoating, these contaminants
will not be plated onto the job. Less sanding will be required and there will be a
subsequent reduction in dirt contamination in other processes. The net effect of
decreasing dirt contamination will ultimately lead to increased production counts through
the paint shop.

THE BASICS OF WELD BALL AND METAL CONTROL

Metal contaminant control needs to be accomplished in cleaning/degreasing stages of

the phosphate system.

• Stages 1 & 2 should provide 1500 gpm and 1000 gpm deluge respectively, at
entrance and exit
• Deluge risers and nozzles should be configured to deliver approximately 50% of the
fluid volumes to the interior, always on the inclines and declines in the system
• The use of proper filtration is necessary to eliminate metal contaminants from the
process solution, or use magnetic polishers to collect metal and to induce attraction
of metal to form aggregates which can be filtered
• Control in cleaning stages should also be continued in the second half of the system
• Establish a 20 micron maximum size for weld balls and other metal contaminants in
process solutions
• Preventing Elpo contamination is critical in order to prevent weld balls and metal
contaminants from plating within the electrocoating process
• Attached weld balls can only be controlled in the body shop

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

PROCESS

Weld ball and metal contaminants present a very significant problem on horizontal
surfaces. The dynamics of weld ball problems on horizontal surfaces can be best
explained by a “skimming” effect that carries contaminants forward through the system
and causes floating weld balls to deposit. In addition, these weld balls that are not
removed from the job in the phosphate system will contaminate Elpo.

The weld balls that cause problems on vertical surfaces are usually attached to the job
and can only be controlled in the body shop.

Fluid Volumes

To reduce overall dirt concentrations, the process should provide large volumes of fluid
at an incline prior to the application of the phosphate coating. The recommended
amount of deluge volume is 1500 GPM per angle with a minimum of 50% of that volume
inside of the job. Data shows that deluge on the incline and decline is especially
important for flushing particles through the rear of the vehicle. For existing systems, the
installation of deluge on any inclines or declines will have a positive impact on the
removal of metal from the interior.

Process Tanks

Weld balls have some unique characteristics due to the way they are formed in metal
joining processes. A significant number of weld balls have air trapped inside of them,
and smaller sizes actually hold air around them for some length of time. Consequently,
tanks with an overflow have a significant reduction in metal concentrations in the top 2
inches of the process solution. This removal of floating metal is instrumental in
preventing contamination of stages downstream in the process.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

Fishbone Diagram for Weld Ball Variation

MATERIAL EQUIPMENT
Filter Size/Construction

Tank Overflow
FILTRATION
Oil on Steel PHOSPHATE
SYSTEM
Filter Area/Media Efficiency
Dryness of Oil
Magnets/Polishers
Galvanized Fluid
Volume Incline/Decline
WELD BALL
VARIATION
Tip Cleanliness
Mig Welding

BODY SHOP Tank Cleaning Magnet Cleaning

Laser Cutting Frequency

METHODS PERSON ENVIRONMENT

The fishbone diagram above illustrates some of the variables that have an impact on
weld ball and metal variation in the processing of a vehicle.

Please refer to Chapter 3, Plant Area Checklists.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

Comparative Sizes - Weld Ball Target Size vs. Paint Films

Clear Coat

Tolerable Weld Ball

Elpo Film

Basecoat

Waterborne

Size
Primer Film

Basecoat Film

Size Target

Weld Ball
1.1 mils 1.0 mil 0.8 mils 0.4 mils 1.8 mils 1.97 mils .78 mils

(27.9 µ) (25.4 µ) (20.3 µ) (10.2 µ) (45.7 µ) (50 µ ) (20 µ )

This figure illustrates the allowable particle size for weld ball and metal contamination,
and a target control size based on nominal filters. Results of studies indicate that
although a 20 micron particle will not break the basecoat, an agglomeration of 20
micron particles is readily visible. On the average, a 50 to 60 micron weld ball will break
the basecoat.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

EQUIPMENT

Filter Types

Bag Filters. A variety of bag filter vendors have been evaluated in a qualitative and a
quantitative filter study involving several critical performance attributes. The study was
focused on bag filter construction and in-plant test trials to determine if there are
significant differences. The data suggests that all bag filters will push material through
the media at increased pressure differential; however, some perform better under load.
Weld balls, in particular, are readily pushed through due to their geometry. A report
summarizing the performance of current bag filter vendors is available at Paint
Engineering.

Pressure Filters. From the data collected from testing, pressure filters have proved
superior to other types of filtration at maintaining acceptable sludge concentration
levels. Maintaining low sludge concentration is essential for applying an adequate
phosphate coating; furthermore, the removal of sludge is a critical element in metal
control due to the metal content of the sludge.

Centrifugal/Cyclone Separators. Initial studies indicate that there is a question of

reliability with the use of cyclones in filtration of phosphate system process fluids. A
study conducted at a GM assembly plant showed that if centrifugal separators are not
operated under correct conditions, they are ineffective at removing contamination. They
are easily plugged with sealer and require a specific pressure differential for operation.
This limited study showed that the backflush of the system was cleaner than the
process flow; however, other data from Europe indicates effective operation is possible.
More evaluation is required to determine if a more robust system exists; however, the
particle size that can be effectively removed is estimated to be greater than 80 microns.
This method of filtration is most effective above 200 microns and has no effect on lint or
other low specific gravity particles.

Amiad Filters. These filters can be used effectively on the cleaning stages. These
filters are automated; consequently, the reduction in maintenance time would be very
beneficial to most facilities. These filters can readily reach an absolute micron rating of
80, thereby removing the load from filters in subsequent stages in the process.

Electromagnetic filters. In some cases, metal contaminants are not 100% magnetic.
Many have a high carbon content, others are generated in the silicon-bronze application
in the body shop and contain few magnetic components. These paramagnetic materials
can be collected with this technology since a 2000 gauss electromagnetic filter will
generate up to 10,000 gauss in sections of the matrix. A 2500 gauss electromagnetic
filter is effective at removing weld balls to a 10 micron level. Consequently, the use of
these polishers on the cleaning stages would provide a clean feed to the final spray
halos and reduce the large numbers of weld balls and metal shavings that eventually
contaminate the Elpo system.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

Magnets

Data shows that the use of magnets in the process will have a profound effect on the
metal concentration and defects related to metal contamination. The studies indicate
that magnets installed inside bag filters increase the efficiency of the bag in two ways:
by catching metal as it passes by the magnet, and by magnetizing small metal particles
so they aggregate and get captured in the filter media.

An effective use of magnets in controlling weld balls is the installation of magnets into
the weir. This has shown to be effective at several locations; however, an appropriate
cleaning schedule must be adopted to insure the effectiveness of the magnets.

Magnets in bag filters are another way to separate metal particulate from process
solutions. Instead of using bag filters with pockets for magnets, many facilities have
devised a simple tool that is designed to hold three magnets in the bag filter. A simple
design would allow for flow through the center of the bracket to minimize turbulent flow
and to allow for large contact areas. The bracket is made so that the magnets can easily
be removed through the top and the whole assembly can be readily removed from the
bag.

A critical parameter when considering magnet use is the cleaning schedule. A 6000-
8000 gauss magnet will collect down to 25 microns; but as a magnet becomes loaded
with metal, the effective gauss drops and collection size rapidly increases to 100-200
microns and above. The plants showing the best results carry 150-250 magnets with a
cleaning frequency from 2 to 4 production hours.

Handle is sized to
match the diameter of
bag to suspend the
device in the bag.

Magnet - extending the

length of the bag.

A ring to hold magnets

equidistant.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

Filter Sizes

Comparison of a large number of GM assembly plants has enabled Paint Engineering to

propose target dirt concentrations and recommended filtration levels to achieve these
concentrations.

Proposed Target Dirt Concentrations and Recommended Filter Sizes.

Stage Target Dirt Concentration Recommended Filtration

(mg/L) µ) [nominal]
Size (µ
Stage 1 2 80-100
Stage 2 1.5 50
Stage 3 0.8 25
Rinse Conditioner 0.4 *50
Phosphate 50
Post-Phosphate Rinses 5 25
Chromate Rinse 5 50
Recirculated DI 0.1 25
Fresh DI 0.05 10

*Chemical suppliers recommend a minimum of 100 micron filters in stage 4 which is

inadequate to reach a concentration of .4 mg/L. The use of 100 micron filtration,
assisted with magnets, is recommended or use 50 microns with the possibility of
increasing chemical costs.

MAINTENANCE

Tanks

According to follow-up studies conducted at GM facilities, there is a correlation between

the dirt concentration and the dump/clean frequency of the stage in question. By
increasing the cleaning frequency of stage 1 from once every 8-10 weeks to once every
4 weeks, one GM facility was able to reduce the dirt concentration by nearly 50%. The
actual method of cleaning the tank can also have a significant influence on the metal
concentrations. Systems that have vertical pumps on the feed tanks have very high
accumulations of weld balls in the pump well. Also, a very high accumulation is
sometimes observed at the liquid level line in the feed tank. This level line accumulates
with mill oils and holds metal contaminants at the tank wall. When the system is
recharged, there is the possibility that these contaminants could go into solution.

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Paint Engineering Chapter 5 – Contamination Control Guidelines,
Paint Shop Contamination Control Guidelines Procedures, And Best Practices

Overall Dirt Concentration Data for a GM Facility in Stages 1,2,3

2
1.8
1.6
1.4
1.2 4/10/96
mg/L

1 3/23/95
0.8 NAO Targets
0.6
0.4
0.2
0
Stage 1 Stage 2 Stage 3
(dip (spray (spray
cleaner) cleaner) rinse)

**This table compares dirt concentration levels and the changes that were observed
after adopting a more frequent cleaning schedule.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

CHAPTER 6 – COMMUNICATING EFFECTIVELY WITHIN THE TEAM

Almost everything you do to control contamination involves some kind of communication
— whether you are working with a co-worker to understand a problem or reporting your
findings to contamination control management. Communication is one process that
must be used throughout the paint shop.

Effective communication is essential to problem solving and is the foundation upon

which all teamwork is built; it creates respect, trust, and good working relationships.
Improving communication improves teamwork. This enhances the team’s image,
performance, and overall efforts to prevent contamination. Everybody loves a winning
team. Contamination control management is no exception. A successful team will be
more visible and better supported by the company’s executives.

Like anything else communication is a learned skill. You can learn to become a better
communicator. How? All you need to do is follow the simple advice provided in this
chapter.

This chapter covers communication methods, tips, and general guidelines. Skill building
in specific areas can be accomplished through GMU courses. Contact the appropriate
training coordinator or the GMU web site for course descriptions and registration.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

COMMUNICATING EFFECTIVELY

Communicating effectively within the paint shop provides several benefits:

• Better contamination control

• Credibility for the team
• Team synergy
• Financial support
• Paint shop contamination control management support

Sometimes the most effective communication is done with your mouth closed. A
session with the team is not an opportunity to admire the sound of your own voice while
tearing down the input of your partners. Team meetings should concentrate on the
needs of the entire group. Open dialogue and an easy “give and take” within every team
is important. This synergy can be developed by respectfully listening to the input of all
team members. This will contribute to a winning team by making sure everyone is on
the same page.

Everyone in the company is working toward the same goal; that is, to put out the highest
quality product possible. This means that other groups within the corporation are not
your enemy. Information sharing with other work groups, within the division, and
throughout the company often creates good will within the company and interest in what
your team is doing. This often results in contamination control management support.
Quite often finances for important projects and activities are the rewards for a
successful team.

We communicate in order to accomplish something. Communication methods are

chosen to:

• Get/Give directions • Convey • Make decisions

• Get/Give advice • Convince • Settle disagreements
• Get/Give direction • Motivate • Change opinions
• Get/Give feedback • Inspire • Gain support
• Get/Give information • Emphasize • Take action

Effective communication also:

• Saves time/money
• Improves quality
• Reduces reruns (reprocess)
• Builds corporate knowledge

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

COMMUNICATION METHODS

There are many methods of communication. Some have great impact. Some methods
have a specific purpose. For instance, presentations work better to communicate with a
large number of people while fax, phone, or face-to-face conversation is better with a
few individuals.

These methods adapted from several GMU courses for Contamination Control can
improve how you are perceived, help you communicate your thoughts or concerns, and
even help you to sway your team members. Perceptions are very important. Your
communication with others can be greatly improved by the skilled use of any of these
tools:

• Phone/Fax/Voice-mail
• E-mail
• Written reports
• Newsletters
• Web site
• Mentoring and coaching
• Team synergy (process)
• Team training
• Team meetings/presentations/minutes

Training Tips
Communication Courses

For more information and skills consider taking these courses:

COURSE NO. COURSE TITLE

058 Interpersonal Negotiating Skills
665 One on One Communication Skills
15292 Coaching for Success
17443 Interpersonal Communincation Skills

17451 Handling Difficult Situations

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

Below is a summary of various communication methods you can use throughout your
dealings in the plant environment or in and around the paint shop.

Method Strengths Weaknesses Usage

Phone • Networking tool • Can be • Contact
• Actual discussion of unprepared contamination control
contamination Subject Matter
problems and Experts (SMEs)
solutions • Personal long
• Informal tool distance
• Timely communication
• Use when issues
occur
Fax • Informal tool • No one-on-one • Allows preparation of
• Timely conversation all questions and
information
beforehand
Voice-mail • Can reach people • No one-on-one • Allows preparation of
when they are away conversation all questions and
information
beforehand
E-mail • Can reach people • No one-on-one • Use when issues or
when they are away conversation questions occur
• Timely • Can be • Follow-up phone
• Can reach many at misunderstood calls
once • Attach larger
documents
Written reports • Can be clear and • Reception of • Specific audiences
concise information is • Clarification
• Detail when needed dependent on • Approval of many
• Informal or formal when the report • When input or
• Writing builds is read – not feedback is needed
credibility instantaneous • Documentation of
• Builds teamwork • Time ⇒ Observations
• Use for consuming ⇒ Action taken
presentations ⇒ Resolutions
• Use as reference ⇒ Lessons learned
⇒ Best practices
• Status reports

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

Method Strengths Weaknesses Usage

Newsletters • Contamination • Costly • To inform large
control news to • Time numbers of people
entire paint consuming • Inform general
population audiences
• Can provide the
right information at
the right time
Web site • Can be used • Initial • Global information
globally development sharing
• Can be used to can be costly • Global news
share and gather • Must constantly • Global net meetings
information update
• News to entire • High
population development
• Can provide the costs
right information at
the right time
Mentoring and • Transfer of • Time • For training and
coaching knowledge from consuming developing skills and
expert to novice knowledge over long-
• Valuable one-on- term
one communication • Building relationships
Team synergy • Can accomplish • Time • When a common
(process) more with more consuming goal or problem
people exists
• Greater problem- • When more than one
solving potential person is needed to
• Many perspectives implement a solution
on the problem • Building teams
Team training • Consistent learning • Time • Building consistent
for entire team consuming team knowledge
• Team off line
during training
Team • Can accomplish • Time • When a common
meetings and more with more consuming goal or problem
presentations people (preparation exists
• Greater problem- and • When more than one
solving potential presentation) person is needed to
• Many perspectives implement a solution
on the problem • Building teams

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

Method Strengths Weaknesses Usage

Team meeting • Documentation • Not often read • After all meetings
minutes • Confirm decisions • Time • Assign responsibility
made consuming • Summarizes meeting
• Defines • Not always
responsibility distributed
• Documents action • Subject to
items interpretation
• Can be delivered via
e-mail, fax, or mail

COMMUNICATION TIPS

Effective Contamination Control starts with communication. The exchange of ideas

spurs new innovations in methods and techniques for preventing the Contamination of
the product. In the end, communication guarantees that our customers will get the best
possible product from General Motors.

The following tips, also adapted from several GMU courses for Contamination Control,
are a guide for basic workplace communication. Greater depth and detail for any of the
tips can be found in specific GMU communication courses. Please contact the
appropriate training coordinator or the GMU web site for course descriptions and
registration.

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

Communication Tips
Effective Feedback

Guidelines for giving effective feedback are:

• Acknowledge the need for feedback

• Give both positive and negative feedback. Negative feedback is not a bad thing if
done in the right way. Make your criticism constructive.
• Understand the context
• Know when to give feedback to contamination team
• Know how to give feedback to contamination team
Be descriptive
Avoid labels
Avoid exaggeration
Don’t be judgmental
Talk about yourself
Talk about what you know for certain
Make sure people hear and accept your compliments
• Know how to receive feedback from the team, contamination control
management, etc.
Listen carefully
Clarify what you hear
Acknowledge the feedback
Acknowledge the valid points
Sort out what you heard

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

Communication Tips
Effective Coaching Skills

Basic skills for effective coaching are:

• Use PACT
• Position meeting (Dirt meeting, quality meetings, etc)
• Assess situation
⇒ Use effective questioning techniques
⇒ Check for understanding through reframing and summary
⇒ Convey sincerity with tone of voice
⇒ Seek to understand behavior and motivation
⇒ Adjust approach to maximize effectiveness
• Create options
• Take action (create action plan)

Communication Tips
Effective Listening Skills

When listening, always follow this order:

• Hear - Listen to the message

• Understand - Clarify what was said
• Interpret - Attempt to determine the basis of information
• Respond - Take action

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

Communication Tips
Effective One-On-One
Communication

Basic behaviors for effective one-on-one communication are:

Visual Qualities

Eye Facial Purposeful Vocal W ord

Goals Contact Expressions Gestures Posture Dress Qualities Choice Organization Rapport
Confident • • • • • • • •
Enthusiastic • • • • • •
Credible • • • • • • • • •
Interesting • • • • • •
Friendly • • • • • •
Dynamic • • • • • •
Inspiring • • • • • •
Sincere • • • • • •
Organized •

Communication Tips
Gathering Information

Basic skills for effective information gathering are:

• Use open ended questioning to:

Gain general information
Encourage conversation
Gather general information

• Use closed ended questioning to:

Gain yes or no response
Limit conversation
Gather specific information

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

Communication Tips

Giving Instructions

Basic skills for giving instructions are:

• Get the listener’s attention

• Maintain eye contact
• Avoid assumptions about what is known
• Establish rapport
• Use clear, simple language
• Avoid jargon
• Use analogies
• Use complete sentences
• Use common terminology
• Clarify information given
• Invite questions

Communication Tips
Non Verbal Communication

Consider your use of effective non verbal communication:

• Use eye contact

• Use good posture
• Show attentiveness
• Consider formal vs. informal stance
• Consider open vs. closed posture

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Paint Engineering
Paint Shop Contamination Control Guidelines Chapter 6 – Communicating Effectively Within the Team

Communication Tips
Effective Presentation Skills

Basic guidelines for effective presentations are:

• Use clear, simple language

• Use descriptive words, examples, and analogies
• Use interesting vocabulary
• Avoid acronyms
• Avoid fillers
• Gain rapport
• Match visual and vocal message
• Use appropriate visuals (transparencies, handouts, posters, flip charts etc.)

Communication Tips
Effective Meetings

Basic guidelines for conducting effective meetings are:

• Prepare and use an agenda

• Warm-up (optional)
• Have members introduce themselves (first meeting)
• Review team’s purpose (first meeting)
• Explain meeting goals
• Define roles (first meeting)
• Set ground rules for meetings and project
• Complete agenda
• Assign action items for next meeting
• Agree on next steps
• Set-up next meeting
• Write and distribute meeting minutes if necessary

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

APPENDIX A - TROUBLESHOOTING

The dirt in paint shop is caused by two separate origins:

• Body Shop
• Paint Shop

There is one way to eliminate dirt:

• At the Source

All areas of the body shop and paint shop can create or contribute to contamination or
dirt on the vehicles. This document will go through the following areas and hopefully be
of use to the users in their attempt to root cause dirt sources.

1. Body Shop 11. Primer Application

2. Phosphate 12. Primer Ovens
3. Elpo 13. Prep Booth Sanding Area
4. Elpo Oven 14. Solvent Wipe
5. Elpo Strip-Out Bank 15. Blow Vac
6. Elpo Sand 16. Feather Dusters
7. Sealer 17. Topcoat Application
8. Solvent Wipe 18. Topcoat Ovens
9. Blow Vac 19. Three Step Finesse
10. Feather Dusters 20. Repair Deck

Many of the above stated contamination points can add dirt to a vehicle or remove dirt
from a vehicle. This document will provide an in-depth view of each area, which should
aid in decreasing dirt in paint and contamination knockdowns. What you will find though,
is that most of the dirt is created or removed by people. Operators are the main
contamination points, but they are also the main source of dirt removal.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

BODY SHOP

Problem Solution
Body shop is the root 1. Re-orient (re-teach) the welding robot path to
cause of weld spatter. minimize weld spatter from hitting the problem areas.
2. Apply an anti-weld spatter material to the problem
areas.
3. Shield the problem areas from weld spatter.
4. Dress weld tips.
Body shop is the root Body shop should remove all evidence of dunnage from
cause of dunnage marks. the metals surfaces. The pre-phosphate washer is not
designed to specifically remove dunnage areas.
Body shop is the root 1. Body shop needs to inspect and verify that the
cause of some sealer vehicles being sent to paint have been sealed to
misapplications specifications. Misapplied sealer results in
contaminating the contamination of the phosphate systems.
vehicle. 2. Paint shop needs to inspect and reject all vehicles
that are not welded correctly and to specification
before they are received in phosphate.
Body shop is the root 1. Need to be inspected before they leave the body
cause of dings and wavy shop. All dinged or wavy metal should be rejected
metal. before the vehicles enter the paint shop.
2. All vehicles need to be inspected before they enter
the paint shop. The time to repair wavy or dinged
metal is before the pre-phosphate washer to ensure
corrosion resistance.
Body shop expandable All vehicles need to be inspected before they leave the
sealer is on class A body shop. All sealer on class A surface is to be
surface. removed before the vehicles leave the body shop.
Ooze out occurs on hem Remove material in the body shop that is causing ooze
flanges of all doors out of the inner doors.
(inner).

Note: When the body shop sends the paint shop vehicles that have one of the problems
stated above, the paint shop must remove the defect. Removing the defect is normally
accomplished by sanding. Sanding creates dirt.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

PHOSPHATE

Problem Solution
The vehicles are Contact the body shop and inform them of the problem.
unusually dirty entering
the phosphate system.
The phosphate system 1. The metal is streaky because the parts are not
leaves streaky metal. wetting properly.
2. Verify temperature and concentration of baths and
rinses.
3. Verify that all rinses are operating properly.
The dunnage marks are 1. Contact the body shop and report dunnage marks on
not being removed. vehicles.
2. Verify temperature and concentration of baths and
rinses.
The vehicles are dirty 1. Verify that the vehicles are not being held between
after the phosphate phosphate and Elpo too long. Phosphate-only jobs
system. tend to be dirt magnets.
2. Verify filters have been changed and the filter sizes
are correct.
3. Verify pumps are running properly.
4. Verify tank levels are correct.
5. Verify bath temperatures are correct.
6. Verify that all rinses are operating properly.
7. Verify that all bath concentration levels are correct.
8. Contact supplier.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

Elpo

Problem Solution
The vehicles are entering 1. Contact the phosphate system and report the dirty
the Elpo system dirty. vehicles.
2. Walk the conveyor line from the Elpo tank back to
stage 8 of the phosphate system, looking for
contamination sources.
The vehicles are leaving 1. Verify filters are clean and filter sizes are correct.
the Elpo system dirty. 2. Verify pumps are working properly.
3. Contact supplier.
4. Verify rinses are working correctly.
5. Verify bath temperatures are correct.
6. Verify bath concentration levels are correct.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

Elpo Oven

Problem Solution
Vehicles entering the 1. Walk the system back through to the Elpo rinses to
Elpo oven are dirty. determine if contamination is from the conveyor or
other obvious system.
2. Contact the Elpo lab and inform operators of the
problem.
The vehicles exiting the 1. Verify that the vehicles entering the oven are clean.
Elpo oven are dirty. 2. Monitor magnehelic gauges for oven filter media.
Normally a reading above 1.0 inches of water
indicate dirty filters.
3. On the weekend, verify that the oven filters are
installed correctly and are operating efficiently.
4. On the weekend, verify that condensate is not
dripping onto vehicles. Condensate normally builds
up at the entrance and exits of the oven walls and
ceiling.
5. During an extended downtime, schedule an oven
cleaning. Vacuum and tack off for minor
dirt/contamination problems, or a chemical clean for
major dirt/contamination problems.

Revised: 10/12/00 A-5

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

Elpo Strip-out Bank

Problem Solution
Vehicles are dirty 1. Verify that the vehicles exiting the Elpo oven are
entering the Elpo Strip- clean.
Out Bank. 2. Inform management of the situation.
Vehicles exiting the bank 1. Walk the conveyor lines of the bank, looking for roof
are dirty or contaminated. leaks and/or conveyor drip pan leaks. (There may be
puddles on the floor.)
2. There are no conveyor drip pans at the bank
entrance split and at the bank exit merge.
3. Verify that conveyor lubricators are off. Contact
maintenance and verify that the correct (silicone
free) lubrication was used.
4. Verify that the doors to the roof are closed.

Revised: 10/12/00 A-6

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

Elpo Sand

Problem Solution
Vehicles are entering the 1. Verify that the vehicles leaving the sheet metal
Elpo sand booth dirty or transfer deck clean.
contaminated. 2. Verify that the operators on the transfer deck are
wearing the appropriate gloves and coveralls.
3. Replace the gloves and the coveralls that the
operators are wearing on the sheet metal transfer
deck.
4. Verify that the cab transfer and box transfers are not
contaminating the vehicles.
5. Verify that there are no leaks from the roof/air ducts
that would contaminate the vehicles.
6. Verify that the RSA door studs are not dripping Elpo
onto the rocker. Contact the body shop and paint
superintendent.
The Elpo carrier is 1. Verify that the Elpo sanders are using the correct
leaving dirt/contamination sandpaper, DA sanding equipment, coveralls,
on the vehicle. gloves, etc.
2. Replace the equipment the Elpo sanders are using.
The Elpo coating has 1. Inform the body shop of the problem. The body shop
body shop sanding marks is using a sandpaper grit size that is too coarse.
telegraphing through the 2. Inform the paint superintendent.
film.

The vehicles are leaving 1. Verify correct air house operation. Water is in floor
the Elpo sand area dirty. pans.
2. Verify that the operators are following the correct
procedures.
3. Verify that the operators are using the correct

Revised: 10/12/00 A-7

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

Problem Solution
equipment.
4. Contact any equipment vendors that are necessary.
5. Notify the superintendent of any problems.
6. Contact the body shop for body shop issues (ooze
out, expandable sealer, sandscratch, weld slag).
7. Institute moist sanding.

System Verification

Before the vehicles leave the thumbgrade deck, the vehicles should be free of all body
shop defects, which include:

• Weld spatter
• Excessive expandable sealer
• Poor metal fit
• Dings in the metal

If there is a problem with any of these areas, contact the body shop then contact the
paint superintendent.

The vehicles should also be free of defects on or in the phosphate and Elpo coating.
These defects include streaks, dirt in the Elpo coating, foam residue from the Elpo and
Elpo cleaning stages, overbake from the Elpo oven, poor appearance from the Elpo
process, residue dripping onto the vehicle from the Elpo carrier, oil or other
contaminants on the Elpo surface. If there is a problem with any of these defects,
contact the shift superintendent.

Tack rags are designed to pick up dirt, sanding dust, etc. Solvent wipers are not
designed to pick up dirt. Solvent wipers are designed to remove oils, fingerprints, sealer,
and the like.

All areas of the vehicle need to be inspected including rocker panels, inner box tailgate,
and all exterior surfaces.

Revised: 10/12/00 A-8

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

SEALER

Problem Solution
The vehicles coming from 1. Verify that all operations are being performed
Elpo sand are dirty or correctly in the Elpo sand area.
contaminated. 2. Verify that the vehicles are not being contaminated
from overhead conveyors or from leaking roof.
3. Verify that the operators are not contaminating the
vehicles with their clothing, hairspray, deodorant,
colognes, perfumes, and lotions.
4. Institute a coverall policy.
The sealer is stringy 1. Verify sealer paths. Re-teach paths if necessary.
and/or spitting on the 2. Verify sealer pressures. Verify sealer viscosity.
vehicles.
3. Remove sealer on manual deck and/or solvent wipe
booth.
The sealer tooling is 1. Verify that the tools are clean. “Clean” means free
contaminating the from cutting oils, metal shavings, old paint old sealer,
vehicles. etc.
2. Verify that the tooling (little man, tailgate, etc.) is
being installed in the correct position.
3. Verify that the wipe down tooling is the correct
tooling being used.
4. Contact process engineering or the shift
superintendent.

Revised: 10/12/00 A-9

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

SOLVENT WIPE

Problem Solution
The solvent wipe 1. Move the tailgate solvent wipe operation to an area
operators cannot reach upstream of the solvent wipe booth.
the tailgate. 2. Shorten the platform so the wiping operation will
have a big enough footprint to complete the job.
3. Lengthen the solvent wipe booth.
The solvent wipe process 1. Verify that the correct solvent wipe is being used.
is streaking the vehicles. 2. Verify that the operators are following the correct
solvent wipe procedure.
3. Verify that the vehicle is not contaminated prior to
solvent wipe.
4. Solvent wipe with different batch number of solvent
wipers.
5. Verify that the operators are not contaminating the
vehicle.
6. Contact the supplier.
7. Contact the superintendent.
The vehicles leaving the 1. Verify that the vehicles entering the solvent wipe
solvent wipe booth are booth are clean.
dirty or contaminated. 2. Verify that the operators are following the correct
solvent wipe procedure.
3. Verify that the operators are using the correct
solvent wiping equipment.
4. Verify that the operators are wearing the correct
protective equipment.
5. Verify that all tooling (RSA door tooling, little man,
etc.) is clean and free of paint residue, oils, etc.

Revised: 10/12/00 A-10

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

SYSTEM VERIFICATION

Before the vehicles leave the solvent wipe booth, the vehicles should be free of all body
shop defects, which include:

• Weld spatter
• Excessive expandable sealer
• Poor metal fit
• Dings in the metal

If there is a problem with any of these areas, contact the body shop then contact the
paint superintendent.

The vehicles should also be free of defects on or in the phosphate and Elpo coating.
These defects include streaks, dirt in the Elpo coating, foam residue from the Elpo and
Elpo cleaning stages, overbake from the Elpo oven, poor appearance from the Elpo
process, residue dripping onto the vehicles from the Elpo carrier, oil or other
contaminants on the Elpo surface. If there is a problem with any of these defects,
contact the shift superintendent.

The vehicle should be free of any sealer defects including sealer stringers, unbrushed
sealer (see PAD document for specific areas), brushed sealer (see PAD document for
specific areas), dirt, oils, and other defects.

Tack rags are designed to pick up dirt, sanding dust, etc. Solvent wipers are not
designed to pick up dirt. Solvent wipers are designed to remove oils, fingerprints, sealer,
and the like.

All areas of the vehicle need to be inspected including rocker panels, inner box tailgate,
and all exterior surfaces.

Revised: 10/12/00 A-11

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

BLOW VAC

Note: Contamination from equipment is normally repetitive. An operator will see the
contamination on the same area of the same body styles. If the contamination is not
repetitive, the contamination is probably not from a piece of mechanical equipment.

Problem Solution
The jobs are entering the 1. Verify that the jobs leaving the solvent wipe booth are
blow vac contaminated dirty.
or dirty. 2. Contact the shift superintendent, wipe booth with a
tack rag, then with a solvent wiper.
The blow vac is 1. Turn off the blow vac until the contaminating sources
contaminating the can be eliminated. If there is only partial
vehicles. contamination, disabling an individual arm may be
implemented.
2. Clean blow vac during a downtime or break when
blow vac is accessible.
3. Verify that the booth supply and exhaust air is on and
working properly.
4. Verify that the blow vac supply and exhaust air is on
and working properly.
5. Verify that the ion bars are working properly.

Revised: 10/12/00 A-12

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

FEATHER DUSTER

Note: Contamination from equipment is normally repetitive. An operator will see the
contamination on the same area of the same body styles. If the contamination is not
repetitive, the contamination is probably not from a piece of mechanical equipment.

Problem Solution
The feather duster is 1. Retract the feather dusters. Run the system in
contaminating the bypass.
vehicles. 2. Verify feather crush. 1-2 inch crush is ideal. More
than a 2-inch crush can deposit the natural oils of the
feather onto the vehicle. The natural oils will leave a
streaky appearance after paint application. Not
enough crush and the vehicle may be dirtier than it
was before it entered the feather duster zone.
The feather duster is 1. Turn off the feathers. Run the system in bypass until
leaving feathers on the the feathers can spin on the weekends. Normally this
vehicles. is a 24-hour break in period.
2. Verify roller path. The feathers should not be touching
wet sealer or sharp metal that can pull feathers out of
the roller.
3. Verify that the feather duster rollers have been
changed. The rollers are changed normally during an
extended shutdown. If the feather rollers have not
been changed, schedule a roller replacement. New
feathers will have the tiny 1/8” feathers intact. Old
feathers will have a worn out appearance and the 1/8”
feathers will have disappeared.
4. Verify that the roofs are clean. The top feather roller
is not to touch any wet sealer that may have been
applied to the roof.

Revised: 10/12/00 A-13

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

Problem Solution
The vehicles entering the 1. Verify that the vehicles are leaving the feather duster
primer surfacer booth clean.
are dirty or 2. Verify that filtered air from the air supply house is
contaminated. supplying air to the tunnel between the robot booth
and the feather duster.
3. Check the crush of the feather duster. It may be
incorrect.
4. Verify that tunnel doors are closed.
5. Verify that the ionized air halo is operating correctly or
turned off.

Revised: 10/12/00 A-14

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

PRIME BOOTH

Problem Solution
The vehicles leaving the 1. Verify whether the dirt is in the primer or not. To do
primer surfacer booth this, check the other booth and look at the same color
are dirty or or primer. If the same color of primer is dirty in both
contaminated. booths, check the primer mix room for circulation
problems. Contact the process engineering or
maintenance.
2. While in the mix room, verify system pressure. Before
and after the filter should be less than 10 psi. If the
pressure is more than 10 psi, have the filters
changed. Beware, if the differential pressure is zero,
the filter bag may have already broken and the
system is contaminated. Change the filter bag.
3. Verify that the primer temperature and viscosity are
correct. If they are not, call a paint mixer to adjust
them.
4. Verify that the Fanuc robots are spraying at the
desired fluid and air pressures.
5. Verify that the air caps are operating correctly on the
robots.
6. Verify that the bells are spraying at the correct fluid
and air pressures.
7. Verify that the air houses are operating correctly.
8. Verify that the filters in the air houses and in the
plenum are installed correctly.
9. Verify that the water flow in the booth is even and
unbroken.
10. Verify that the airflow in the booth is in balance.
11. Verify that the oven is in balance.
12. Verify that the booth temperature and humidity is at
desired setpoints.
13. Verify that the robot and bell paths are correct. Re-
master or re-teach the robots if the paths are
incorrect.
14. There is the option of running the booth in degrade
mode and “X”ing out bells.
15. There is also the option of handspraying vehicle.

Revised: 10/12/00 A-15

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

PRIMER OVEN

Problem Solution
The job is exiting the 1. Verify that the vehicles are entering the oven clean.
primer oven dirty. 2. Normally, condensate (an oily, amber colored liquid)
builds up at the entrance and exit ends of the Elpo
and primer ovens. The condensate will build up on
the walls and ceiling of the ovens and drip onto
vehicles. This condensate must be removed
periodically to avoid vehicle contamination.
3. Monitor magnehelic gauges for oven filter media.
Normally a reading above 1.0 inches of water
indicates dirty filters.
4. On the weekend, verify that the oven filters are
installed correctly and are operating efficiently.
5. During an extended downtime, schedule an oven
cleaning. Vacuum and tack off for minor
dirt/contamination problems, or a chemical clean for
major dirt/contamination problems.

Revised: 10/12/00 A-16

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

PREP BOOTH MANUAL SANDING AREA

Problem Solution
The vehicles are 1. Verify that the prep booths are exiting the primer
entering the prep booths ovens clean.
dirty or contaminated. 2. Walk the line from the prep booths upstream to the
primer ovens and/or the repair deck verifying that the
vehicles are not being contaminated by roof leaks,
conveyor lubricators, etc.
The vehicles are exiting 1. Verify that the sanders are using the correct moist
the sanding area dirty. sanding equipment.
2. Verify that the sanders are using all necessary tools
to clean the vehicles including solvent wipers and
tack cloths.

SOLVENT WIPE

Problem Solution
The solvent wipe 1. Verify that the correct solvent wipe is being used.
process is streaking the 2. Verify that the operators are following the correct
vehicles. solvent wipe procedure.
3. Verify that the vehicle is not contaminated prior to
solvent wipe.
4. Solvent wipe with different batch number of solvent
wipers.
5. Verify that the operators are not contaminating the
vehicle.
6. Contact the supplier.
7. Contact the superintendent.

Revised: 10/12/00 A-17

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

Problem Solution
The vehicles leaving the 1. Verify that the vehicles entering the solvent wipe
solvent wipe booth are booth are clean.
dirty or contaminated. 2. Verify that the operators are following the correct
solvent wipe procedure.
3. Verify that the operators are using the correct solvent
wiping equipment.
4. Verify that the operators are wearing the correct
protective equipment.
5. Verify that all tooling (RSA door tooling, little man,
etc.) is clean and free of paint residue, oils, etc.

SYSTEM VERIFICATION

Before the vehicles leave the thumbgrade deck, the vehicles should be free of all body
shop defects, which include:

• Weld spatter
• Excessive expandable sealer
• Poor metal fit
• Dings in the metal

If there is a problem with any of these areas, contact the body shop then contact the
paint superintendent.

The vehicles should also be free of defects on or in the phosphate and Elpo coating.
These defects include streaks, dirt in the Elpo coating, foam residue from the Elpo and
Elpo cleaning stages, overbake from the Elpo oven, poor appearance from the Elpo
process, residue dripping onto the vehicle from the Elpo carrier, oil or other
contaminants on the Elpo surface. If there is a problem with any of these defects,
contact the shift superintendent.

Tack rags are designed to pick up dirt, sanding dust, etc. Solvent wipers are not
designed to pick up dirt. Solvent wipers are designed to remove oils, fingerprints, sealer,
and the like.

All areas of the vehicle need to be inspected including rocker panels, inner box tailgate,
and all exterior surfaces.

Revised: 10/12/00 A-18

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

BLOW VACS

Problem Solution
The vehicles entering the 1. Verify that the prep booth sanders are removing all of
blow vacs are dirty or the dirt, sanding dust and contamination before the
contaminated. vehicle enters the blow vac.
2. Verify that the blow vac is operating correctly by
checking the supply air, exhaust air, and ion bars.
3. Contact the shift superintendent.
The blow vac is 1. Turn the blow vac until the contaminating source can
contaminating the be eliminated. If there is only partial contamination,
vehicles. disabling an individual arm may be implemented.
2. Clean blow vac during a downtime or break when
blow vac is accessible.

FEATHER DUSTER

Note: Contamination from equipment is normally repetitive. An operator will see the
contamination on the same area of the same body styles. If the contamination is not
repetitive, the contamination is probably not from a piece of mechanical equipment.

Problem Solution
The feather duster is 1. Retract the feather dusters. Run the system in
contaminating the bypass.
vehicles. 2. Verify feather crush. 1-2 inch crush is ideal. More
than a 2-inch crush can deposit the natural oils of the
feather onto the vehicle. The natural oils will leave a
streaky appearance after paint application. Not
enough crush and the vehicle may be dirtier than it
was before it entered the feather duster zone.
3. Verify that the booth supply and exhaust air is on and
working.
4. Verify that the feather duster supply and exhaust air
is on.
5. Verify that the ion bars are working properly.
6. Verify that the beater bar is in the correct position.
7. Vacuum the feathers.
8. Alcohol wipe the feathers. (This solution is not
intended to occur regularly. Frequent alcohol wiping
the feather lowers the lifespan of the feathers.)

Revised: 10/12/00 A-19

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

Problem Solution
The feather duster is 1. Turn off the feathers. Run the system in bypass until
leaving feathers on the the feathers can spin on the weekends. Normally this
vehicles. is a 24-hour break in period.
2. Verify roller path. The feathers should not be touching
wet sealer or sharp metal that can pull feathers out of
the roller.
3. Verify that the feather duster rollers have been
changed. The rollers are changed normally during an
extended shutdown. If the feather rollers have not
been changed, schedule a roller replacement. New
feathers will have the tiny 1/8” feathers intact. Old
feathers will have a worn out appearance and the 1/8”
feathers will have disappeared.
4. Verify that the tape and repair masking bags are not
being caught up in the roller. If this is happening,
contact the repair deck supervisor.
The vehicles entering the 1. Verify that the feather duster, blow vac, and prep
mod clean room are dirty booth sanders are removing all of the defects.
or contaminated. 2. Verify that the prep booth sanders are tacking off the
vehicle.
3. Verify that the vehicle is being solvent wiped.
4. Check the crush of the feather duster. It may be
incorrect.
5. Verify that the ionized air halo is operating correctly or
turned off.

Revised: 10/12/00 A-20

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

TOP COAT

Problem Solution
The vehicles leaving the 1. Verifty whether the dirt is in the topcoat or not. To do
mods are dirty or this, check other booths and look at the same color of
contaminated. topcoat. If the same color of topcoat is dirty in other
booths, check the mix room for circulation problems.
Contact the process engineering or maintenance.
1A. While in the mixroom, verify system pressure.
The pressure readings before and after the filter
should be less than 10 psi. If the pressure is more
than 10 psi, have the filters changed. Beware, if the
differential pressure is zero, the filter bag may have
already broke and the system is contaminated.
Change the filter bag.
1B. Verify that the primer temperature and viscosity
are correct. If they are not, call a paint mixer to adjust
them.
2. Verify that the Fanuc robots are spraying at the
desired fluid and air pressures.
3. Verify that the air caps are operating correctly on the
robots.
4. Verify that all booth doors are closed.
5. Verify that the air houses are operating correctly.
6. Verify that the filters in the air houses and in the
plenum are installed correctly.
7. Verify that the water flow in the booth is even and
unbroken.
8. Verify that the airflow in the booth is in balance.
9. Verify that the oven is in balance.
[Link] that the booth temperature and humidity is at
desired setpoints.
[Link] that the robot and bell paths are correct. Re-
master or re-teach the robots if the paths are
incorrect.

Revised: 10/12/00 A-21

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

Problem Solution
The vehicle is exiting the 1. Verify that the vehicles are entering the oven clean.
topcoat oven dirty. 2. Monitor magnehelic gauges for oven filter media.
Normally a reading above 1.0 inches of water indicate
dirty filters.
3. On the weekend, verify that the oven filters are
installed correctly and are operating efficiently.
4. During an extended downtime, schedule an oven
cleaning. Vacuum and tack off for minor
dirt/contamination problems, or a chemical clean for
major dirt/contamination problems.

THREE STEP FINESSE

Problem Solution
The vehicles entering the 1. Verify that the vehicles exiting the mod ovens are
finesse deck are dirty or clean.
contaminated. 2. Verify that the vehicles are not being contaminated
from an overhead conveyor, duct, water line, etc.
3. Verify that on the two-tone vehicles all tape, body
bags, and masking film are removed.
Containment 1. Remove the dirt using the three-step finesse process.
2. Knockdown the parts of the vehicle that are not
finesseable and route the vehicle to the repair deck.
3. Swap out the un-finesseable parts of the vehicle with
parts that are stored in the spare part banks.
4. Remove the surface contamination (drips on the
cured painted surface) with a solvent wipe or tack
cloth and re-inspect the vehicle.
5. Contamination that is not on the surface and cannot
be finessed should be knocked down and routed to
the repair deck.

Revised: 10/12/00 A-22

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix A - Troubleshooting

REPAIR DECK

Problem Solution
The vehicles entering the The vehicles are routed to the repair deck because they
repair deck are dirty or are dirty or contaminated.
contaminated.
The vehicles exiting the 1. Stop the conveyor and prep the vehicles correctly.
repair deck are dirty or Implement DA sanding, hand sanding, tacking and
contaminated. solvent wiping to clean up the vehicles. All vehicles
leaving the repair deck should be ready to spray.
2. Contact the paint shift superintendent.
3. Blow the vehicle through the deck until the job can be
processed correctly.
The body bags on Tape the vehicles in a way that will not allow tape or
vehicles are being body bags to get wrapped up in the feather roller.
caught in the feather
dusters.

Revised: 10/12/00 A-23

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix B – Plant Assessment

APPENDIX B - PLANT ASSESSMENT

PAINT SHOP CONTAMINATION CONTROL FOUR MAIN FOCUS

AREAS

PEOPLE

Utilize Principles of Paint Shop Contamination Control Guidelines

PROCESS

Utilize Principles of Paint Shop Contamination Control Guidelines and Appropriate

Process “Best Practices”

MATERIAL

Utilize Only Approved Direct/Indirect Materials

FACILITIES

Utilize “Bill of Process” and “Facilities Technical Specifications”

Note: Evaluate all areas “Red, Yellow or Green” based on the following requirements

Revised: 10/12/00 B-1

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix B – Plant Assessment

KEY ISSUES IN THE PEOPLE AREA

Green Yellow Red
• “Dirt Awareness” Training for All Paint Shop
Employees

• Self-inspection/Clean-up on All Operations

• Approved Attire Including Hair Protection on

All Paint Shop Employees

• Approved Gloves on Everyone in Contact

With Vehicle

• Food/Smoking Only in Enclosed

break/cafeteria Areas

• No fibrous material in paint shop

(newspapers, paper towels, cardboard, etc.)

• Functional dirt/contamination control team in

place

• Only approved indirect materials utilized

• Strive to eliminate all lint-containing

materials

• All employees responsible for the personal

housekeeping of their area

• Create people and vehicle traffic patterns

that minimize the potential to contaminate
vehicle
• Consider entire paint shop a “clean area”

Revised: 10/12/00 B-2

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix B – Plant Assessment

KEY ISSUES IN THE PROCESS AREA

Green Yellow Red
• Total process operation based on paint shop
common process control plan

• Utilize synchronous/5S workplace

organization

• Filter change process, booth/oven cleaning

schedule, etc. based on statistical data

• Use defect prevention to minimize sanding

using only spot moist defect sand

• Consistent fill/level control process for paint

mix tanks

• Preventative maintenance, cleaning and

balancing of paint circulating systems

• Develop continuous cleaning process for

tools, fixtures, carriers and skids

• Incoming material control for dirt, fibers and

craters

• Maintain 50% RH as a minimum level in all

paint shop environments at all times

• Utilize only approved indirect materials

• Immaculate housekeeping and continuous

facility and equipment cleaning/repainting
• All facility/equipment installations must
include a deep clean process

Revised: 10/12/00 B-3

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix B – Plant Assessment

KEY ISSUES IN THE FACILITIES AREA: EXISTING PLANTS

Green Yellow Red
• All paint booths located in a minimum-sized
cleanroom

• Minimize cleanroom access with air shower

entries only

• Sanding and finesse/polish in enclosed

booths with wet pan floors and negative air
balance
• Protect vehicle with a clean tunnel or canopy
in all critical areas

• Dryers coalescing filters and oil vapor

elimination for compressed air supply to
paint shop
• Maintain a positive air flow sequence (i.e.
booths>cleanroom>paint shop>outside)

• All booth enclosure penetrations must be

sealed

• Controlled single entry point to paint shop

through garment change area

Revised: 10/12/00 B-4

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix B – Plant Assessment

KEY ISSUES IN THE FACILITIES AREA: NEW PAINT SHOPS

Green Yellow Red
• All facilities/equipment based on paint
engineering BOP and technical
specifications
• Low contaminant generating conveyor
systems (i.e. pendulum, skids)

• Floor conveyors begin at e-coat oven

• All paint booths located in a minimum-sized

cleanroom

• Minimize cleanroom access with air shower

entries only

• Paint booth quality air supplies for

cleanroom

• Clean-wall designs for bells and robot rails

• Temperature and humidity control in paint

mix room (ambient air temperature must be
below paint temperature)
• Sanding and finesse/polish in enclosed
booths with wet pan floors and negative air
balance
• All booth enclosures penetrations must be
sealed

• Bottom entry indirect fired ovens

• Protect vehicle with a clean tunnel or canopy
in all critical areas

• All paint carriers confined to paint shop

Revised: 10/12/00 B-5

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix B – Plant Assessment

KEY ISSUES IN THE FACILITIES AREA: NEW PAINT SHOPS,

CONTINUED
Green Yellow Red
• All floors and exposed concrete sealed

• Dryers, coalescing filters and oil vapor

• Elimination for compressed air supply to

paint shop

• Blow downs for compressed air headers

with drip legs at all drops

• Motor and agitator compressed air exhaust

into contained headers

• Maintain a positive air flow sequence (i.e.

booths>cleanroom>paint shop>outside)

• Air cooling, if required, for work areas (no

man fans)

• Enclosed/air conditioned break areas

• Wash basins and hot air dryers (no paper

towels) in break areas

• Controlled single entry point to paint shop

through garment change area

Revised: 10/12/00 B-6

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix C – Common Contaminants

APPENDIX C - COMMON CONTAMINANTS

List as of April 2000

Problem Materials Suggested Items

Personal Products1

Deodorants & Antiperspirants Deodorants

Almay Anti-Perspirant Deodorant Almay Solid Stick (Hypoallergenic)
*Arm & Hammer Antiperspirant Amplex Dry Stick
Arrid Extra-Dry Antiperspirant Spray Arrid Extra-Dry Roll-On
Arrid Extra-Dry Solid Arrid Extra-Dry Roll-On
Arrid Xx Antiperspirant Spray Asda Cool Sport Aerosol
Arrid Xx Stick Asda Cool Sport Dry Stick
Arrid Aerosol Asda For Men Aerosol
Ban Clear Asda Stay Cool Dry Stick
Ban Roll-On3 Avon Wild Country (Roll-On)
Ban, Wide Solid Anti-Perspirant & Body Fresh Aerosol
Deodorant
Degree Antiperspirant Body Mist Aerosol
Gillette Clear Gel Brylcream Aerosol
Gillette Dry Idea Scented Roll-On Dial Roll-On
Gillette Right Guard Solid Dry Stick Gillette Right Guard Scented Deodorant
Stick
Gillette Right Guard Sport Stick Gillette Right Guard Sport Deodorant
Stick
Gillette Soft & Dry Gillette Right Guard Stick
Imperial Leather Aerosol
Insignia Aerosol
Kyomi Aerosol
Lady’s Choice (All Forms) Lynx Aerosol
Kyomi Dry Stick
Mennen Lady Speed Stick Mennen Dry Stick
Mennen Lady Speed Stick (Roll-On) Mennen Speed Stick (Solid)
Mennen Musk Speed Stick Mennen Speed Stick Deodorant
Mennen Speed Stick Antiperspirant Mennen Speed Stick Sport Deodorant
Mitchum, Men's Nova Dry Stick
Mum Aerosol
Old Spice Stick Antiperspirants & Old Spice AP-2 Blue Stick Deodorant
Deodorant
Right Guard Sport Deodorant Old Spice Stick Deodorant
Sante Aerosol
Secret
Secret Aerosol Real (Smooth On Cream)

Revised: 10/12/00 C-1

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix C – Common Contaminants

Problem Materials Suggested Items

Secret Anti-Perspirant Deodorant
Secret Antiperspirant Roll-On
Soft & Dry Super Solid
Soft And Dry Antiperspirant Spray
Sure (All Forms) Suave Roll-On
Tussy
*Tommy Stick Deodorant By Tommy
Hilfiger
*Ultra Ban Scented Antiperspirant
Spray

General Comments:
Note similar names on under crater causing and non crater causing materials
in general, all anti-perspirants will cause a defect. Look for these ingredients that
are crater causing agents: Silicone, Dimethicone, Cyclomethicone, Aluminum
Chlorhydrate, Aluminum Hydroxy Chloride, Aluminum Ziconyl Hydrochloride,
and Aluminum Zirconium Tetrachlorohydrex Gly(Cine). Please wear gloves at all
times when you are in contact with the vehicle, and change them periodically to
ensure they stay clean.

Hair Styling Products

Aveda Shampoo And Crème Rinse Aussie
Breck 14 Hour Hold
Clairol Final Net Ultimate Hold Clairol Mist Regular
Condition By Clairol Hairspray
Condition By Clairol Mousse Flex Hair Spray
Fantasia Liquid Mousse Hair Spray Helene Curtis Extra-Hold Salon
Selective
Final Net Salon Selective (See Helene Curtis)
Kenra Hair Conditioner Suave Hairspray
L'oreal Studio Line3 Suave Styling Mousses
Pantene Shampoo And Conditioner White Rain
Paul Mitchell Hair Spray Vo-5 Crystal Clear

General Comments:
Hair Sprays In General Should Not Be Applied On The Line. Please Confine
Their Use To The Restrooms.

Generally Hair Sprays Will Cause Bubbles When Applied To Surfaces.

Revised: 10/12/00 C-2

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix C – Common Contaminants

Problem Materials Suggested Items

Body Lotions/Hand Cleaners &
Creams
Aloe Vera Triple Lanolin Brut Splash-On Lotion
Avon Moisture Therapy Hand Cream Calgon After Bath Lotion
Avon Silicone Glove Clinique Facial Cleanser
Baby Oils Corn Huskers Hand Lotion4
Boraxo Hand Soap
Brylcream Aerosol
Cleanup Waterless Hand Soap
Cure'l Moisturizing Lotion
Dermashield Barrier Cream
Jean Nate Body After Bath Splash Jergens Protective Cream Sbs4 (Before
Elpo)
Jergen's Hand Lotion Johnson's Baby Powder
Keri Original Formula Keri Lotion
*Kroger Skin Care Lotion Lectric Shave
Jergens Advanced Therapy Lotion Mennen Medicated Skin Cream
Lubriderm Hand Lotion Mennen Medicated Skin Cream
Noxema Skin Cream Nivea Cream
Oil Of Olay Moisturizer Oil Of Olay Hand Cream
Penetone Protective Cream 411 (After Penetone Cream 411 (Before ELPO)
ELPO)
Pond's Cream & Cocoa
Pond's Extra Rich Pump Petro Jelly By Us Pharmaderm
Raintree Dry Skin Lotion Shower To Shower Deodorant Body
Powder
Raintree Hand Lotion
Reach Hand Cleaner
Soft Sense
St. Ives Swiss Formula Dry Skin Lotion St. Ives Swiss Apricot Scrub
Suave
Suave Skin Therapy Lotion Suave Skin Therapy Lotion
Vaseline
Vaseline Baby Powder
Vaseline Hand & Nail Lotion
Vaseline Intensive Care Foam Bath
Vaseline Intensive Care Lotion
Wondra Deep Moisture

Revised: 10/12/00 C-3

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix C – Common Contaminants

General Comments:
People shed skin on a continuous basis. If there is a strong airflow toward the
job from a person using a strong crater causing product, such as those above,
their skin pieces, if contaminated, are likely to cause craters.

Problem Materials Suggested Items

Cologne
English Leather
Imperial Leather Aerosol
Jovan Sex Appeal
Lynx Aerosol

Miscellaneous Items:
Clinique Lipstick Ammens Talk Powder
Downey Fabric Softener Blistex
Mary Kay Face Powder Chapstick
Snuggle Singles Mennen Talc Powder
Bath & Body Works Anti-Bacterial Soap
Gel
Neosporin Antibacterial Treatment

Direct Materials

Production Materials
Siliconized Backing Paper

Indirect Products
Production Materials
3m 280 Sandpaper
3m 77 Adhesive
3m Edge Sealer
3m Glaze 06992 Glazing Compound
Burmah 8914 Defoamer
Cl-371 Defoamer
Norton #10 Disk Adhesive
Norton Gasket Material
Parco 14 Defoamer
Fomegon 961

Revised: 10/12/00 C-4

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix C – Common Contaminants

Problem Materials Suggested Items

Maintenance Materials
American Industrial #32 Compressor Oil
Behr Compressor Oil Dwyer Red Gage Oil
Behr Pail Oil Ssl-46 Ler01
Belz 234 Air Additive
Belz 349 Air Additive
Belz 356 Air Additive
Bostick 1581 Silicone Sealant
Calgon C3 Refrigerant Oil
Canepus Oil #46 (Texaco)
Chemlube 201
Clm 7-11 Air Additive
Clm-615 Grease
Coon-Divisser Compress Oil
Dolchem Sealant 7061
Dop, Dioctylphtalate7
Formax Belt Grease F1
Friske Brothers Lubriplaste Oil #8
General Electric Industrial Sealant
Graco 4yd Pump Lub
Graco Air Lub 10w Oil
Hy Oil 941
Ici-Tribol 40ls Is0220
Kent Seam N Caulk Sp
Kill Frost Anti-Freeze Lubricant
King's Dobsa Catalyst
Koch Material Aluminastic-C Metallic
Compound
Krytox Dupont®
Loctite 495 Adhesive
Lubecon Series #1 Chain Oil
Lubecon Series Ast S-Lubricant
Mobil Dte Hydraulic Oil
Mobil Dte Light Lubricating Oil Isovg32
Mobil Plex 46 Grease
Molbualloy Chain Oil 22
Moluballoy 310
Moluballoy 322
Moluballoy 802
Moluballoy 910
Molubally Gear Oil 90
Molykote Silicon Lt. Grease

Revised: 10/12/00 C-5

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix C – Common Contaminants

Nut - Off
P&F Carrier Shock Absorber Oil
Phillips 66 Super Hd Ii Sae 40
Pure ISW -32
P-80 Rubber Lube
Rainbow Glass Cleaner
Rando HD 46
Rando Hydraulic Az
Regal Oil R&O 220
Regal Oil R&O 46
Rigid Nu-Clear Thread Cutting Oil
70835 Jacobsen
Shell Tellus Oil #46
Shell Tellus Oil 10
Single Phase Prelube Pl7105a
Slide"No-Rust" Rust Preventer
Spindura Oil #10
Spindura Oil #22
Swak Teflon Pipe-Joint Compound
Texclad #2
Thiemile 711 Feather Fluid
Tribol 943AW
Ursa Super Plus Sae 30
Wc 2291 Esbm 2c53a2 Corrosion
Preventer
Wd-403
Zep (Zep 45) Lubricant W/Te
Cleaning Materials
Alpenco Eye Glass Cleaner
Armorall
Digital Hard Surface Cleaner K-Lens-M Pink
Furniture Polish Aerosols Magic Ter'n Wipe Lense Cleaner
Mistron Eye Glass Cleaner Pink Eye Glass Cleaner
No Fog Sight Saver Eye Glass Cleaner
(Bausch&Lomb)
Pc 2960 (Detergent) Wetted Lens Tissue (Foil Pack)
Rain Away
Rainbow Glass Cleaner
Silicone Paper Magic Glass Lens Wipe
Vision Air Glass Cleaner
Yellow Eye Glass Cleaner
Zep Furniture Polish
Zeper Stainless Clean Polish
Zepride (Degreaser)

Revised: 10/12/00 C-6

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix C – Common Contaminants

Textiles & Related Materials

Rigger And Chukka Boots (5)
Velcro (6)
Most High Speed Machine Sewn
Textiles (6)
Most Knitted Fabrics (6)
Most Embroidery Badges (6)

Other
Some Foam Sealing Strips W/
Siliconized
Backing Paper
6068 Caulking From Dolchez
Abc Fire Extinquisher Powder Ansul 50 Abc Fire Extinquishers
All Valves (Unless Ordered Dry)

Food
Fried Chicken
Popcorn
Potato Chips

Note:
These can be eaten, but hands should be thoroughly washed with approved
soap before returning to work.

Revised: 10/12/00 C-7

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix C – Common Contaminants

Notes:

1. Personal products may combine with body chemistry to produce variable results.
2. Ban Roll-on is an Anti-perspirant containing aluminum chlorhydrate but did not
cause craters because of a carrier coating. This may change while being worn (See
Note 1).
3. Talc was found to be present in abundance at the center of craters (Produced by
Soft & Dry anti-perspirant) through the use of an SEM-EDS (SEM-Energy Dispersive
X-Ray Spectroscopy) test.
4. The craters produced by a mixture of cyclomethicone and talc are very similar to
those produced by anti-perspirants which supports the fact that talc acts as a carrier
for the cyclomethicone.
5. These materials appear as crater causing on plant lists but could not be made to
cause craters in laboratory tests. (Ban Roll-on has high surface tension carrier)
6. No cratering or read out excellent results.
7. These types of products are usually contaminated by silicone mold parting
compounds.
8. Most high volume sewing, stitching and knitting operations use a silicone oil lubricant
to improve machine performance and to avoid needle cuts in the fabric which will
cause early stitch failure. Paint shop materials need to be manufactured on
machinery lubricated with water soluble oils
9. Compressed air filtration retainers with excess DOP if manufactured poorly will emit
DOP droplets.

Revised: 10/12/00 C-8

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix D – Start-Up Procedure After Extended Shut Down

APPENDIX D - START-UP PROCEDURE AFTER EXTENDED

SHUTDOWN
Following annual paint shop shutdowns; the paint shop must be prepared for restart to
prevent contamination. Instructions for start-up after extended shutdown include the
following areas:

• Body shop washer/highlighter

• Pre-phosphate operations
• Phosphate/Elpo systems
• Sealer
• Prep booths and feather dusters
• Ionize blowoff
• Powder primer systems
• Prime, topcoat and final repair equipment
• Spraybooths and air supply house
• Ovens
• Paint circulation systems

BODY SHOP WASHER/HIGHLIGHTER

• Make sure it’s operational

• Check filters, concentrations of cleaner
• Contact supplier representatives for additional information

PREPHOSPHATE OPERATIONS

• Have personnel on prewipe deck evaluate and perform supplemental cleaning as

required
• Have phosphate suppliers recommended material on hand to remove oxidation if
needed

WARNING: In some cases, acid wiping for rust removal will be required. “Oleum” decks
that drain back to pre-clean tanks or reservoirs will be contaminated by the acids used
for rust removal. Each Oleum deck must be examined to safeguard their system from
this potential.

• Allow sufficient time to fill and adjust tanks prior to start up

• Complete all boil outs if previously scheduled
• Contact supplier representatives for additional information

Revised: 10/12/00 D-1

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix D – Start-Up Procedure After Extended Shut Down

PHOSPHATE

• Install filters
• Charge system
• Ensure proper chemical concentrations
• Start system early enough to ensure up to temp/pressure
• Walk all conveyor paths to ensure clearances for carriers and/or bodies
• Have cleaner stations at maximum concentration to clean any oils or contamination
on jobs
• Contact supplier representatives for additional information

ELPO

• Reinstall filter bags/institute monitoring program until system stabilizes

• Check all process parameters (solids, pH, etc.)
• Contact supplier representatives for additional information

SEALERS (BODY AND PAINT)

• Review expiration dates of all material (replace if necessary)

• Bleed all drops to ensure virgin material
• Check all pressures, including individual drops
• Cycle equipment and seal a job to validate parameters if possible

PREP BOOTHS AND FEATHER DUSTERS

• Inspect feathers and clean/change if necessary

• Refill all wet pans and start circulation
• Bleed all air lines
• Restart all fans and air supplies early
• Check voltage, rpm, vacuum, profile, etc.
• Check downdraft and booth balance

COMPRESSED AIR STARTUP PROCEDURES

• Inspect system low points (drip legs) for moisture and/or oil and blowdown if
necessary for approximately one hour
• Inspect all coalescent filter bowls for oil smears and if necessary clean with solvent
and blow down that system for approximately one hour
• Verify all automatic drain traps are functioning, especially for the compressor
aftercooler and dryer separator

Revised: 10/12/00 D-2

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix D – Start-Up Procedure After Extended Shut Down

IONIZE BLOWOFF

• Bleed all air lines

• Run all blowoffs for a minimum of two hours and then clean equipment and filters
before production
• Check voltage and clearance

POWDER PRIMER SYSTEMS

• Verify that temp/humidity has been maintained in booth/storage areas. If not,

perform panel sprayouts for quality check
• If powder was left in hoppers boost fluidization air by 50% for approximately one
hour to assist powder conditioning before spraying
• Confirm particle size

PRIME, TOPCOAT, AND FINAL REPAIR SPRAY EQUIPMENT

• Reinstall bell cups and air caps

• Start all fans, humidifiers, etc.
• Ensure proper booth downdraft, balance, temp, humidity and adjust as necessary
• Validate all process parameters (fluid flows, rpm, shaping air, atomization air, fan
patterns, etc.)
• Ensure all pots/guns are clean before filling
• Refill pots/guns with fresh materials
• Don’t necessarily throw out old paint; it may be a better match for old paint left in
main system

SPRAY BOOTHS AND AIR SUPPLY HOUSES

• Have everything operating 48 hours before start of production to allow stabilization

• Confirm balance at least 6 to 8 hours in advance, including ovens, booths, and clean
rooms
• Have sludge operating 48 hours in advance with chemical supplier present
• Have chemical supplier treat humidifiers 24 hours in advance of production

Revised: 10/12/00 D-3

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix D – Start-Up Procedure After Extended Shut Down

OVENS

• Walk ovens before starting jobs to check ducts and access doors
• Restart all oven burners according to manufacturer’s start-up procedure
• Have ovens in operational mode 24 hours in advance; once OK, leave it in setback
mode if empty; if there are jobs in them, get them to operational mode then turn
them off and leave the fans on and refire once production starts
• Run data packs on first jobs through oven
• Confirm oven balance 6 to 8 hours before production

ABATEMENT

• Verify filterhouse and oven/booth abatement equipment operation is in “online”

status 48 hours before start of production for booths and 24 hours before for ovens

PAINT CIRCULATION GUIDELINES FOR EXTENDED SHUTDOWN

• All paint circulation systems should be refilled and circulated for a minimum of 24
hours before production begins. If startup validation vehicles are processed through
prime and topcoat (and they should) then the systems should be running 24 hours
before the validation vehicles are processed
• Do not add cold or hot paint to the system >20 F° from set point without testing and
approval of the paint supplier. All paints should have been stored in an environment
that will maintain the temperature close to operational set point. Waterborne
basecoat undergo irrevocable damage if exposed to temperatures above 100 deg or
below freezing. Waterborne paint systems should have shut down with paint left in
the lines. It is preferable to leave the mix tanks low at shutdown
• Replace paint circulation filters prior to production. Carefully monitor system
pressures and flow rates for the first 24 hours of circulation
• Check paint viscosity and temperature during startup and make adjustments as
required
• If the paint was removed from the circulation system and the system flushed with
solvent. It is important to fill the system with fresh materials at a slightly higher
viscosity to compensate for the solvent left in the system. It also makes sense from a
robustness point of view to start with new materials. The paint removed and stored
can be added as replenishment over time
• Insure solvent materials removed from the mix tanks and stored in totes are properly
agitated prior to putting into the mix tanks

Revised: 10/12/00 D-4

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix D – Start-Up Procedure After Extended Shut Down

SPECIAL CONSIDERATIONS FOR BODY PREPARATION AFTER

EXTENDED SHUTDOWN
SPECIAL NOTE: The startup after extended summer shutdown is very critical. Vehicles
produced during this time will likely be those vehicles used for all the important quality
indices such as J.D. Power. It is therefore critical that we maintain normal high level of
shipping standards and that we implement a high level of containment to insulate
customers from potential defects.

OIL DRIPS

(Pertains to all in process jobs after Elpo.)

Any extended shutdown provides a high potential for vehicle contamination with oil, dirt,
and other debris. In addition, any contractor work has the potential to result in damage.
All vehicles in process should be checked for damage and appropriate corrective
actions should be taken. Oil droplets from conveyors or other sources should be wiped
with a solvent moist rag. Rags should be discarded frequently to prevent contamination
of non-contaminated surfaces. When removing oil, do not wipe the entire panel with the
initial cleanup rag. Wipe only the contaminated area.

DIRT AND DEBRIS

Vehicles should initially be lightly dry-tacked. Special attention should be paid to gutters,
shelves, and hood/fender flanges, door openings, truck beds or other common areas of
the vehicles for dirt to settle. We do not recommend blowing out these areas prior to
tack-off. Blowoffs should be reserved to automated equipment just prior to your feather
duster. A solvent wipe may be desired, depending upon the air quality or potential for
contamination from plastic or rubber hoses, or other contractor/worker materials. In no
instance except for the spot removal of oil should a solvent wipe precede an initial tack.
Performing the solvent wipe first will often result in smearing the dirt around the surface.
The solvent wipe operation has a high potential for creating defects and must be
performed with extreme care. Use only a supplier recommended solvent and keep the
rags extremely dry and frequently changed. Wiping with a contaminated rag defeats the
entire purpose of performing the operation. The surface should evaporate almost as
quickly as applied. Too wet a wipe may result in wipe marks from differential removal
and redepositing of surfactants or other contaminants. Some primers due to their
inherent surfactant package, plant bakes and other concerns, are too sensitive for
solvent wipe operations to be performed. Consult with your supplier for more
information regarding this topic. An additional tack-off is typically performed after solvent
wipe operations. If you are following the guidelines in regard to wetness of the wipe, this
should be of no concern. Under no conditions should a tack operation take place until all
solvent is flashed from the surface.

Revised: 10/12/00 D-5

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix D – Start-Up Procedure After Extended Shut Down

Note: With the additional tack and wipe operations that are required, special care must
be used to avoid snagging rags on sharp surfaces and leaving strings behind.

PLASTIC COVERS, HOSE, AND OTHER CONTAIMINATION

Whenever plastic or rubber comes in contact with a surface to be painted, the potential
for low molecular weight monomers to transfer to the substrate and act as a
contaminant are likely. Plastic bags used for vehicle storage should be removed
carefully. Avoid dragging the bag across the surface. Hoses should be covered or used
in conjunction with balances to prevent contact with the painted surface. Often the
evaporation pattern, from the solvent wipe operation will be the first clue of this type of
contaminant. In rare circumstances solvent wiping will remove the contaminant.
Contamination usually must be sanded to be removed. The best opportunity to catch
these defects and put in corrective actions is when you run the single vehicle through
the spray booths for system validation.

SANDING OPERATIONS

Extended shutdowns, despite our best efforts, often result in higher dirt counts on the
initial vehicles processed. This often results in more sanding and/or more aggressive
sanding. To avoid discoloration, sand marks, bullseyes, etc. it is important to remember
the following points:

• Avoid machine (D.A., Orbital, etc.) sanding whenever possible

• If you do machine sand, keep the wheel flat, use proper backup pads and papers
• Final cut should always be a maximum of 30 micron or 400 grit
• If you must sand more aggressively, then you must progressively sand back to 30
micron or 400 grit
• If you add more sanding, you must add more cleanup. Pay special attention to
cleanup of gutters, shelves, truck beds, etc.

Revised: 10/12/00 D-6

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix D – Start-Up Procedure After Extended Shut Down

RECOMMENDED VALIDATION OF EACH MAJOR PAINT PROCESS

With the varying layouts of each paint shop, specific plans for validation must be
developed for each plant. The following are guidelines to assure vehicle paint durability
on all units.

PHOSPHATE

• Run test panels on racks and/or scrap bodies prior to production if possible – have
supplier verify results
• Run monthly test panels on first production units – submit them to supplier for testing
ASAP
• Microscopically confirm crystal formation and appearance on scrap body panel
and/or test panels if possible
• Visually review first production units to verify uniformity
• Continue to review phosphate appearance while using “racked” metal that has been
stored during downtime
• If there is any “suspect” metal from the extended downtime, process a sample panel
through the complete paint system (phosphate through topcoat) and perform a bear
claw adhesion test after topcoat. If the resulting panel is OK for surface appearance
and passes the bear claw test, it is OK for production

ELPO

• Run test panels on racks and/or scrap bodies through tank and oven (including Data
Paq) prior to production if possible. Perform solvent run (cure) test and check film
build on these bodies and/or panels
• Run monthly test panels on first production units – submit them to supplier for testing
ASAP
• Run Data Paq and Throw Power Tube on first production unit
• Confirm cure via solvent rub on first production units
• Check film build on first production units
• Visually review first production units to verify uniformity

SEALER

• Apply sealer to test panels on racks and/or scrap bodies and run through oven
(including Data Paq) prior to production if possible. Confirm cure via Data Paq and
perform sealer adhesion test on these bodies and/or panels
• Run Data Paq on first production units
• Perform sealer adhesion test on first production units
• Visually review first production units to verify uniformity

Revised: 10/12/00 D-7

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix D – Start-Up Procedure After Extended Shut Down

PRIMER

• Run test panels on racks and/or scrap bodies through booth and oven (including
Data Paq) prior to production if possible. Perform solvent run (cure) test and check
film build on these bodies and/or panels
• Run Data Paq on first production units
• Confirm cure via solvent rub on first production units
• Check film build on first production units
• Visually review first production units to verify uniformity

TOPCOAT, FASCIA, AND IN-LINE REPAIR

• Run test panels on racks and/or scrap bodies through booths (mods) and oven
(including Data Paq) prior to production if possible. Perform solvent rub (cure) test,
bear claw adhesion test, and check film build on these bodies and/or panels
• Spray out panels of all colors and compare to standard to confirm color match
• Run Data Paq on first production units through all ovens
• Confirm cure via solvent rub on first production units from all ovens
• Have units of each color from each booth (mod) compared to standard to verify color
match
• Check film build on first production units
• Perform bear claw adhesion test on first production units
• Increase frequency of bear claw adhesion test while using “racked” metal that has
been stored during downtime
• Perform bear claw adhesion test on any “suspect” panels prior to running such
panels on production units
• Visually review first production units to verify uniformity
• Check orange peel, DOI, and gloss on each color on first production units

FINAL REPAIR

• Run Data Paq on first production units through oven

• Confirm cure via solvent run on first production units
• Visually review first production units to verify uniformity

Revised: 10/12/00 D-8

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix E – Supplier Forms

APPENDIX E - SUPPLIER FORMS

GENERAL MOTORS PAINT ENGINEERING PAINT SHOP INDIRECT MATERIALS
TEST REQUEST FORM (TRF) PROCESS

1. Product Test Request made by Supplier to Paint Engineering.

2. Blank Test Request Form sent to Supplier by Paint Engineering:
• By mail (or in person)
• By fax only if Supplier has a plain paper fax machine
3. Supplier completes and signs Test Request Form:
• Product Type
• Application Area
• Vendor Name
• Product Description
• Vendor P.O. No. and Common Code (If an active product)
• Vendor Contact
• Product Status
• Reason for Test (Paint Engineering to complete this section if for Supplier
Reduction, Investigate Problem, or Random Audit)
4. Supplier returns completed Test Request Form by mail (Fax is not permitted.
Supplier is not to retain the original copy of the Test Request Form).
5. If Product Test Request is approved, Test Request Form is signed by Paint
Engineering and assigned a Request No.
6. Copy of signed Test Request Form is retained by Paint Engineering and filed in the
Test logbook.
7. Test Request Form information is entered by Paint Engineering in the Paint Shop
Indirect Materials Testing Log.
8. Original copy of the Test Request Form is sent to the Testing Lab.
9. Upon completion of product tests, original copy of the Test Request Form is
returned to Paint Engineering with the test result data.
10. Original copy of the Test Request Form is filed in the Test logbook and the copy
(see 6) is discarded

Revised: 10/12/00 E-1

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix E – Supplier Forms

Note: The original copy of the Test Request Form is filed in the Test logbook and the
copy (See 6) is discarded.

GENERAL MOTORS PAINT ENGINEERING

INDIRECT MATERIALS APPROVAL PROCESS
SUPPLIER INFORMATION
Company:
Address:

Contact Person: Title:

Phone Number: Fax Number:

Please provide the following information on these and/or attached sheets.

! SEE ATTACHED DOCUMENTS

1. Provide the following organization and manufacturing information:

A. Description of your organizational structure with an organization chart.

B. List of your manufacturing process locations.

2. Provide the following information about your manufacturing processes:

A. Describe the manufacturing processes of your product(s) over which you have full
control.

Revised: 10/12/00 E-2

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix E – Supplier Forms

B. Using the attached Manufacturing Process Flow Chart, outline and describe
these processes (See example chart). Use multiple charts, if necessary.

3. ISO 9000 certification will be required for all paint shop indirect material suppliers by
1998.
A. If you are currently ISO 9000 certified, provide your Registration Certificate
Number and a copy of your Registration Certificate.

B. If not:
1. Describe your current status or plans for achieving ISO 9000 certification.

4. GM's objective is to eliminate all cardboard and similar particulate-causing

packaging materials from the paint shop. Describe what plans you have for providing
for fiber-free containerization.

Revised: 10/12/00 E-3

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix E – Supplier Forms

5. Describe your current product distribution process. Indicate any involvement you or
your distributors have in GM's commodities management program.

6. Describe the support services you offer (i.e., technical, laboratory, training,
consulting).

7. At the time of approval for testing, the following products and product information will
be required:
A. Sample of the product from each process location.
B. Material Safety Data Sheet (MSDS)

Revised: 10/12/00 E-4

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix E – Supplier Forms

Paint Engineering Indirect Mat’ls Approval Process Product Information

Company:
Address:

Contact Person: Title:

Phone Number: Fax Number:
PLEASE PROVIDE THE FOLLOWING INFORMATION ON THESE AND/OR
ATTACHED SHEETS.
! SEE ATTACHED DOCUMENTS
Select or describe the type of product you are requesting to have tested.
! Wiper, Dry ! Wiper, Solvent ! Wiper, Presaturated
! Tack Cloth ! Glove, Dry ! Glove, Solvent
! Coverall, Washable ! Coverall, Disposable ! Other
Select or describe where this product would be applied.
! Sealer Application ! Paint Preparation ! Repair
! Maintenance ! Other
Product Name/Number:
Describe the product material, features, etc.

If it is a new product to General Motors, describe the advantages it will offer compared to existing
competitive products in terms of performance, features, cost, etc.

If it is an improvement to a previous product, describe the nature of the improvement(s).

If it introduces new technology, describe the technology and the advantages it will provide.

Provide technical data documenting the product material and performance attributes in the
enclosed General Motors Paint Engineering Laboratory Test Series Requirements. These data
will be verified and compared to General Motors specifications by the laboratory testing.

Revised: 10/12/00 E-5

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix E – Supplier Forms

GENERAL MOTORS PAINT ENGINEERING PAINT SHOP INDIRECT MATERIALS

TEST REQUEST FORM

Product Type: ! Wiper, Dry ! Wiper, Solvent ! Wiper,

Presaturated
! Tack Cloth ! Glove, Dry ! Glove,
Solvent
! Coverall, Washable ! Coverall, Disposable ! Other

Application Area: ! Sealer Application ! Paint Preparation ! Repair

! Maintenance ! Other

Vendor Name:

Product Description:

Vendor P.O. No.: Common Code:

(Active Product Only)
Vendor Contact:
(Name)

(Address)
( ) ( )
(Phone) (Fax)

Product Status: ! Active ! Trial

Reason for Test: ! New Technology ! New Application ! Supplier

Reduction
! Investigate Problem ! Random Audit ! Other

Vendor Approval for

Paint Engineering
To Receive Test Results:
(Name) (Signature)
( ) ( )
(Phone) (Fax) (Date)

Approval to Test
Paint Engineering:
(Name) (Signature)
( ) ( )
(Phone) (Fax) (Date)

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix E – Supplier Forms

THIS BLOCK TO BE FILLED OUT BY TESTING LAB

Received By:
(Name)
( ) ( )
(Phone) (Fax) (Date)
Notification
Package to Vendor:

Testing Scheduled:

Testing Complete:

Report to GM:
(Sent By) (Date)
Report to Vendor:
(Sent By) (Date)

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix E – Supplier Forms

GENERAL MOTORS PAINT ENGINEERING INDIRECT MATERIALS APPROVAL

PROCESS SUPPLIER ACKNOWLEDGMENT

The General Motors Paint Engineering Indirect Materials Approval Process has been
established to maintain a consistent method for testing, evaluating, and controlling the
introduction of all new Paint Shop Indirect Materials into General Motors plants.

General Motors will insist upon total compliance on the part of all materials suppliers in
following the procedures described. No products may be brought to a General Motors
Paint Shop without prior notification and approval of the Paint Engineering
Contamination Control Team. Failure on the part of a supplier to comply with the
provisions of these procedures will potentially result in the refusal of Paint Engineering
to test and approve the new product(s) and may further result in having any products
currently in use removed from the list of approved products.

If you have any questions concerning any part of the Indirect Materials Approval
Process, please feel free to contact any member of the Paint Engineering
Contamination Control Team.

I have read and understand thoroughly the Indirect Materials Approval Process for
having my company's products tested and approved and for introduction to General
Motors Paint Shops and hereby agree to comply with all its provisions.

(Signature)

(Name)

(Company)

(Date)

Revised: 10/12/00 E-8

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

APPENDIX F - GLOSSARY

Abrasive The hard grit on sandpaper and grinding discs.

Acetone A powerful lacquer solvent of the ketone type.

Acrylic A coating based on a polymer containing short chain

esters of acrylic and methacrylic acid.

Adhesion The ability of primer or paint to stick to the applied

surface.

Agglomerate Clumps of pigment crystal, which has formed loose

clusters containing entrapped air. Usually undesirable in
paint since agglomerates tend to settle out and have poor
optical qualities.

Air Cap The structure in front of a spray nozzle, which directs

compressed air against the paint to form and shape an
atomized cloud of droplets.

Air Knife A mechanical blowoff device used to prepare the

surfaces of automobile bodies or parts for painting. In
use, a small amount of compressed air pulls in large
volumes of ambient air to produce a high-flow, high-
velocity curtain or sheet of air (ionized air if an ionizing
bar is used).

Air Membrane Monitor A porous disc through which air is drawn by use of a
vacuum pump. Particles collected on a gridded
membrane filter are examined in accordance with ASTM
F25, allowing determination of particle sizing and
concentration as well as identification of contaminants.

Air Shower An air-lock entryway that uses high-velocity jets of filtered

air to remove loosely held particles from personnel
entering a contamination-controlled area. Loosened
particles are removed by filtration in the
exhaust/recirculation system in order to prevent
contamination by resettling in another area.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Air Spray A system of applying paint in the form of tiny droplets in

the air. The paint is broken into droplets by a spraygun as
a result of being forced into a high velocity air stream.
The shape and paint density of the resulting droplet cloud
can be controlled by air pressure, paint viscosity and gun
tip geometry.

Air-dry Allowing paint to dry at ambient (surrounding)

temperatures, without the aid of an external heat source.

Airflow Movement of air in a given direction with respect to a

specified reference plane or other designated physical
reference

Air-lock Entry A two-door anteroom used to maintain pressure

relationships between adjoining areas.

Airless Spray System of applying paint in which the paint, under high
pressure, is passed through a nozzle and broken into
droplets (atomized) when it enters the lower pressure
region outside the gun tip. A much smaller volume of air
is used than in conventional air spraying so that problems
of dryspray and paint bounceback are reduced.

Aliphatic Solvent A type of solvent comprised mainly of straight chain

hydrocarbons. Examples are gasoline, kerosene, hexad
and naphtha.

Alkyd A coating based on polyester binder. Such polyesters are

chemical combinations of molecules, which contain more
than one acid or alcohol group. They are widely used in
waterbase house paints, automotive primers and general
industrial enamels.

Ambient Air Air that is present in the area of a paint-spray operation

and which may be filtered or environmentally conditioned,
or both.

Appearance The visual quality of a coating as determined by Gloss,

DOI, or Tension testing.

Aromatic Solvents Hydrocarbon solvents with benzene ring nucleus such as

xylol or toluene.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Atomization The form of tiny droplets of liquid as in paint spraying

process. Atomization is usually caused by turbulence in
an air stream or a sudden drop in pressure.

Atomize The extent to which a spray gun breaks up paint into fine
mist, fog or spray.

Automatic Zone The area in a paint-spray booth that uses automated

spray equipment to apply paint.

Basecoat / Clearcoat Base coat is highly pigmented and capable of complete

hiding at a low film thickness. Base coat is normally flat,
the gloss and depth of appearance are obtained by the
application of clear enamel.

Binder The ingredient in paint that holds the pigment particles

together.

Bleeding A lower (older) color coming through a fresh coat of paint.

Blistering The formation of bubbles on the paint surface.

Blowoff The removal of particles and fibers from a surface in

preparation for the application of paint, using compressed
or high-volume, fan-driven air.

Blushing The formation of a whitish or misty appearance on the

finish color.

Booth An enclosure that provides for the supply of fresh filtered

air and the removal of contaminated air. Booths are used
primarily for paint-spray application, but can also be used
for other paint shop processes such as sanding, sealing,
and wiping.

Bouffant A puffed-out head covering used to contain the hair of the

wearer.

Catalyst A chemical which alters and increases the rate at which a

chemical reaction takes place. Hardener acts as catalyst
in the curing of enamel.

Chalking The appearance of a white powder on a paint surface as

it weathers and ages.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Checking, Cracking and Short very fine crack lines that appear in the paint film
Crazing that resemble crow’s feet or shattered glass.

Clouding The appearance of darker and lighter areas, resembling

clouds, in a metallic paint coat.

Coalescence The fusing or flowing together of liquid droplets.

Color (Topcoat) Oven An oven used to bake the topcoat

Compound An abrasive paste or liquid that smoothes and polishes

the painted surface.

Controlled Environment An environment in which parameters such as

temperature, differential pressure, humidity, and
contaminant level are controlled within specified limits.

Convertible Film Former Paint dries through a chemical reaction or conversion

with the aid of oxygen, heat or catalyst.

Crater (Fisheye) A small depression formed in a wet paint film as a result

of localized reduction of surface tension, such as might
be caused by the presence of silicone or other
contaminants.

Crossdraft Air movement in a sideways (horizontal) direction from

supply toward exhaust within a paint-spray booth.

Cross-hatch Coat Checkerboard application of paint to be sure of a

continuous paint film. One medium coat is usually
followed by a second medium coat in a perpendicular
direction.

Cure The process by which paint is converted from the liquid to

the solid state. May be measured by Solvent Rub, Pencil
or Tukon Hardness testing.

Curing The final drying stage where the paint reaches maximum
strength.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Curing Agent Catalyst to produce drying and/or hardening effect.

De-grease Removing wax, silicone and grease from old paint

surface. Wiping with a clean cloth saturated in a solvent
and dry wiping with another clean cloth before solvent
can evaporate. This is essential to good paint adhesion.

De-wax See De-Grease.

Dirt (Contaminant) An undesired inclusion in a paint film, caused by

anomalies or disturbances in the painting process.

Dispersion The resin component in the paint is partially dispersed in

a phase in a non-solvent. Higher application solids are
achieved. The micro particles in this dispersed phase
require higher heat to fuse or cure.

Distinctness of Image The measurement of the clarity of the light image

(DOI) reflected from a painted surface.

Downdraft Air movement in a downward (vertical) direction from

supply toward exhaust within a paint-spray booth.

Dry Film Hiding To determine at what film thickness paint will completely
hide the underlying surface.

Dry-spray Atomize paint that does not dissolve into the material
being sprayed. Causes are holding gun too far from work,
too much air pressure, or solvent that evaporates too
fast.

E-coat A painting process (also known as electrodeposition or

electrocoating) that applies a paint film on all surfaces of
a metallic object, immersed in a bath of water-thinned
paint, when an electric current is passed between the
object and another electrode.

Electrocoating Anodic A process in which a negatively charged paint film is

deposited onto surfaces of substrates. The deposition
occurs as a result of an electric current passing between
the object coated and the oppositely charged electrode
(usually the electrocoat tank walls) while immersed in a
bath of water thinned paint.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Electrocoating Cathodic An identical process to that of anodic electrocoating

except the paint film is positively charged and electrically
deposited on to the surfaces of negatively charged
metallic substrates.

Electrodeposition A process in which a paint film is deposited on all

surfaces of a metallic product by the passage of an
electric current between the object being coated and
another electrode while immersed in a bath of water
thinned paint.

Electrostatic Spray Developed in the early 50s as an application method that

would significantly increase transfer efficiency and
reduce finishing costs. By charging the atomized paint
particles and the surface to be painted that has the
opposite charge, an electrostatic field is created that pulls
the paint particles of the surface. This is achieved with a
minimum of overspray and more uniformity. It also
provides the ability to “wrap around” and paint the
backside of many parts.

Enamel Synthetic Enamels use Alkyd resins, Acrylic enamels use

acrylic resins, and polyurethane enamels use urethane
resins as a binder. Enamels use convertible film formers
and they are thermosetting. They have a natural shine
without the need for application of heat or buffing.
Enamel has a higher solids content compared to lacquer.

Emulsion or Latex Paint Paint film is formed through the evaporation of the carrier
(normally water).

Epoxy A type of paint, adhesive or plastic noted for high

mechanical strength, good adhesion and resistance to
solvents, acids, alkali and corrosion. They do not weather
well.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Esters A type of organic compound used as active solvent for

acrylic lacquers. Examples are butyl acetate and
diethyleneglycol diacetate.

Etching The use of a chemical solution to prepare a surface for

painting or bonding by removing a layer of the base
metal.

Evaporation Solvents in the paint escaping to the air.

Extended-surface Filter A filter in which the effective surface area of the filter
medium is greater than the cross-sectional face area of
the filter. The increase in area is the result of forming the
medium in a characteristic configuration, such as pleats,
rigid cells, pockets, bags, or socks. The filter medium is
typically made of a material such as air- or wet-laid glass
fibers, synthetic polymers, or a cotton-synthetic blend.

Faraday Cage Effect The phenomenon by which charged particles are

prevented from entering recessed areas. It is due to the
curvature of electric force lines in the nearest grounded
surface.

Feather-edge The tapered edge of the paint where it meets the metal.
The edges should be tapered or slanted so that no edge
will be felt when a finger is passed over it.

Fiber A solid object usually defined as having an aspect

(length-to-width) ratio of at least 10 to 1. Common types
and sources of fibers include short filaments of textile
threads, either natural (e.g., cotton or wool) or synthetic
(e.g., nylon or polyester), or a cellulosic material (e.g.,
paper or cardboard).

Filament, continuous A long strand of synthetic material, usually grouped

together in multiples, to form a thread or yarn.
Continuous filaments contrast with natural threads or
yarns of cotton or wool, formed by twisting many short
fibers together.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Filter Pad A section or element of filter medium (or media),

generally supported by a gate-type holding frame, in
which the face and internal airflow velocities are
essentially the same. Filter pads are generally
manufactured from spun-glass fibers, paper, or synthetic
fibers.

Finish Coat The final color coat.

First Run Vehicles or parts that have gone through the complete
paint application process on time and meet final
acceptance criteria.

Fisher Cup A viscosimeter that works like a liquid hourglass. The

viscosity of a liquid is determined by the time it takes to
flow through the opening in the cup.

Fisheye (Crater) Small pits that form in a paint coat, caused by silicone
contamination on the old paint finish.

Flash The first stage in the drying process where most of the
solvent evaporates.

Flash Point The temperature at which the vapor of a thinner or

solvent will ignite in the presence of sparks or open
flame.

Flash Time The time required for a coat of paint to lose most of its
solvent through evaporation.

Flat-felled Seam A seam used in garments where two layers of fabric are
folded over and interlocked so that edges are not
exposed.

Flocculation To form masses of particles either by settling out or

forming a gel.

Fuzziness Lower gloss and DOI resulting from excessive basecoat

film or too dry an application of basecoat.

Fog Coat A fully reduced (thinned) paint that is sprayed at a higher

than normal air pressure or with the gun held at a greater
distance than normal held from the work. The object is to
obtain a fast flash off with minimum solvent penetration
into the old paint.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Glazing Use of putty to fill minor imperfections.

Gloss The measured amount of light reflected by a painted

surface.

Gloss Meter An instrument that measures the degree of gloss of a film

by its reflectance. Most commonly used is a 60° meter.

Gravelometer A device for subjecting a paint panel to impact from air

blown gravel to determine its probable service life and
method of failure. The extent of failure is determined by
counting the number of chips in each of several size
ranges.

Hardener Catalyst in the curing of enamel.

HEPA (High Efficiency A throwaway, extended-medium, dry-type filter in a rigid

Particulate Air) Filter frame, having a minimum particle-collection efficiency of
99.97% (that is, a maximum particle penetration of
0.03%) for 0.3-µm particles of thermally generated DOP
or specified alternative aerosol.

Hiding The ability of a paint to obscure the surface to which it is

applied.

High Solids Paint Paint containing 45 to 80 percent solids. These products

have become popular because of the reduction in solvent
emissions associated with their use.

Hue The name of a color; the property of a color by which it

can be distinguished (red, blue, yellow, etc.).

Indexing Starting or stopping of a cart or carrier operating in an in-

line or rotary mode, by manual or automatic means.

Intercoat Adhesion Determines how well one coat of paint adheres to

another layer of paint or underlying primer.

Ketone As used in paint, these are colorless volatile solvents.

Lacquer Nitrocellulose lacquers use nitrocellulose resins and

acrylic lacquers use acrylic resins as a binder. Lacquers
are non-convertible and they are thermoplastic. Lacquers
require heat application or buffing to obtain a gloss.
Lacquers have a lower solids content than enamels.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Limited-linting (“lint- Term used to describe textiles that have been specially
free”) designed, manufactured, and processed (laundered) to
achieve minimum levels of particulate and fibrous
contaminants. Note: Despite technological advances in
producing and cleaning textiles for contamination-
sensitive applications, these materials are never truly free
of all removable “linting” contaminants.

Lint Small fibers shed or abraded from textile material.

Manual Zone The area within a paint-spray booth in which the

application of paint is performed by people.

Masking The application of paint-impermeable tape or other

impervious material, or both, to protect designated
area(s) of the product from being coated with paint.

Metallic Paint Finish paint colors that contain metallic flakes in addition
to other pigments. Metallic paints have the best hiding
properties.

Metal Prep A mild acid mixed with water wiped over bare metal to
clean and etch prior to priming.

Micrometer (µm) A unit of length in the metric system equal to one-

millionth of a meter (approximately 0.00003937”).

Mil 1/1000 of an inch (0.001”) or approximately 25 Microns in

atomic/molecular terms.

Mist Coat Usually the final color coat, produced by over-reducing

with a slow evaporating solvent. It is usually used to
blend in the final overlap areas.

Monotone Painted with a single color (versus two-tone).

Non-convertible Film Paint dries through the simple evaporation of a volatile

Former liquid. Nitrocellulose lacquers are non-convertible.

OEM Original Equipment Manufacturer.

Revised: 10/12/00 F-10

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

One-stage Paint This polyurethane based enamel uses a high clear

content to simulate the effect of Two-Stage
(basecoat/clearcoat) paint. It can sometimes be used to
blend bc/cc.

Opaque An adjective referring to something which will not let light

pass through.

Orange Peel A rough paint surface, resembling the skin of an orange,

caused by the paint spray failing to flow together.

Original Finish The paint applied to the vehicle when it was built by the
manufacturer.

Overlap The part of the spray band that covers the previous
application of paint. A 50% overlap on each stroke is
generally recommended.

Overspray The fine mist of paint on areas where it is not wanted

(glass, moldings, other painted surfaces, etc.). The
telltale mark of a car that has been painted or had
bodywork done. Overspray is also the mist of paint or
primer that escapes into the air during the spray painting
process.

Oxidation One of the processes by which enamel cures, by

combining oxygen in the air with the paint film. This
process dries and continues to harden enamel for several
weeks. Oxidation also results in chalking in older cars.

Paint A mechanical mixture or dispersion of one or more

pigments, usually opaque, in a liquid or medium.

Paint Film The actual thickness of the paint on a surface.

Paint Mix Room Area where paints are stored, mixed, and dispensed.

Paint Shop Cleanroom The portion of the paint shop, generally isolated by
various methods and encompassing the paint-spray
booths, where controls and restrictions are imposed on
the size and concentration of airborne particles in order
to prevent dirt defects.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Paint Spray The atomization or breakup of paint into tiny droplets of

liquid or particles of powder, usually caused by
turbulence in an airstream, centrifugal force, or a sudden
drop in pressure.

Paint-spray Apparel A set of specified limited-linting articles of clothing and

accessories, typically used in paint shops.

Panel filter A fixed medium air filter, in which the airflow velocity at
the filter face and within the filter medium is essentially
the same. Panel filter media are generally manufactured
from metal filaments, spun-glass fibers, or synthetic
fibers.

Pearlescent Paint A basecoat/clearcoat or two-stage paint containing pearl

or mica pigments in the base. These are not to be
confused with three-stage paints. Pearlescents were a
forerunner of three-stage paints and they offer a less
expensive and easier to repair alternative. The pearl
effect is less pronounced compared to the new three-
stage paints.

Pencil Hardness Various harness levels of graphite are etched across the
surface of paint until indentation of surface is observed.
The highest level of graphite used prior to the etching of
the surface would be considered the pencil hardness of
that coating. This test is usually used in a production
situation.

Percent Nonvolatile The percent by weight of the solid (nonliquid)

(Percent Solids) components in a paint.

Percent Solids The percent mass of a paint due to its non liquid
components.

pH Value The chemical symbol that, together with a number,

describes the alkalinity or acidity of a solution. 7 is
neutral, below 7 indicates acid condition.

Pigment Finely ground powders in the paint that give it its color.

Pigment Volume The amount of pigment, by volume, in the non-volatile

Concentration portion of the paint.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Pitot Tube A device used to determine the velocity pressure of a

unidirectional airstream by simultaneously measuring its
static pressure and total pressure.

Popping A paint defect characterized by raised bumps in the

surface caused by solvent vapor forming within the paint
after it has begun to “skin over.” The resulting vapor
pressure raises the paint surface.

Power Wash A multistage cleaning machine or structure through which

material is transported, using some form of conveyor
system in which the material is cleaned and conditioned.

Prime Coat Primer or surfacer applied to the old paint or bare metal
before the finish coat is applied.

Primer Undercoat that acts as a bond between unpainted

substrate and later paint films. Primers can be sprayed
over old paint. Primers generally do not require sanding.
The word Primer is often used when referring to all types
of sprayable undercoats (primers, primer-surfacers, and
primer-fillers), which can lead to some confusion.

Primer Filler This undercoat is a primer-surfacer based on fast-drying

urethane or polyurethane resins. It can be applied for
regular and high filling requirements. Primer fillers are
catalyzed products.

Primer-surfacer This undercoat has a lot of the same bonding qualities as

a primer but has the additional ability of filling small
imperfections. Primer-surfacers require sanding before
respraying with other paint coats.

Production Aid A device such as a jig, bracket, or clamp used to hold or

support parts or keep them in proper position for painting.

Reducer The solvent that is used to thin enamel.

Resin A thick and sticky substance of natural or synthetic origin

used as binder in paints, varnishes and undercoats.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Resistivity Measures the ability of a liquid to conduct electricity.

Rework a. Parts unable to meet final acceptance criteria which

have been or will be reprocessed through a repair cycle
or paint application.

b. The process of preparing defective painted parts for

repainting, typically by removing surface defects by
sanding or other means.

Run A run is a mass slippage of paint film running in rivulets.

Sag Sag is a partial slippage of paint in the form of curtains.

Sanding Block A block of rubber or plastic to which sandpaper is

fastened, offering the operator a good grip. The block
should be used for most sanding jobs, because it
distributes the pressure evenly and gives a more uniform
surface.

Sand Scratches The marks left in the substrate and undercoats by

abrasives. They may also show in the new finish due to a
lack of filling or sealing.

Sand-scratch Swelling Solvents present in surface scratches that cause the old
finish to swell.

Sealer An intercoat between the topcoat and the undercoats or

old finish, giving better adhesion. Sealers are generally
non-sanding.

Seeding A lumping of pigments or the vehicle becomes gelatinous

forming relatively large particles in the coating.

Settling Pigment in the paint collecting at the bottom of the paint

can or the spray gun container (cup).

Shrinkage The shrinkage of automotive paint as it dries. All

automotive paints shrink, and if scratches or
imperfections have not been properly filled, they will
show up as the paint shrinks into them.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Silhouette A partition or partial wall used to reduce the size of the

opening of the entrance or exitways from paint booths
and tunnels.

Single Coat A coat of paint with each stroke overlapping the previous
stroke by 50%.

Solids The ingredients (pigments and binder) of the paint that

remain on the surface after the solvents evaporate.

Solids Content The measure of the amount of solids in a paint. The

higher the solids content the better the hiding properties
of the paint.

Solvency The ability of a pure or mixed liquid to dissolve resin.

Solvent A fluid that dilutes or liquefies another liquid or solid.

Solvents include thinners, reducers and cleaners.

Solvent Rub Determines the solvent resistance (or cure) or a paint film
by rubbing a solvent dampened cloth over the surface
and scratching the surface with a fingernail.

Spot Glazing Filling minor imperfections (sand scratches).

Stability The resistance of paint to increase in viscosity.

Substrate The surface that is to be refinished. It can be anything

from an old finish or primer to an unpainted surface
(steel, aluminum, fiberglass, etc.).

Surface Dry A condition in which the outer layer of the finish dries
while the underneath remains soft and not thoroughly
dried.

Tack Coat The first coat of enamel that is allowed to dry until
“tacky,” usually about 10 to 30 minutes depending on the
amount and type of reducer used.

Tack Cloth (Tack Rag) A cloth impregnated with non-drying varnish that is used
to pick up dust and dirt particles.

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Tack-off Process The means used to remove particles and fibers from a
surface that is to be painted.

Tacky The surface is tacky when it sticks to the finger when light
pressure is applied.

Telegraphing A hand print, rag marks or hose mark, etc. on one coat
that reads through on a subsequent coat.

Tension The smoothness of a painted surface as determined by

evaluation of the resolution of an image of increasingly
closer parallel lines reflected from its surface (the
smoother the surface, the higher the resolution).

Thermoplastic Refers to a substance (paint or plastic) which is heat

reactive. Heat will soften or liquefy thermoplastic
substances after they are dried or in a solid state.

Thermosetting Refers to a substance (paint or plastic) which is not heat

reactive. Heat will have no effect on thermosetting
substances after they are cured or in a solid state.

Thinner The solvent used to thin lacquer or lacquer based

undercoats.

Three-stage Paint This new type of paint uses a colored base coat, a middle
coat containing pearl or mica pigments, and a clear
topcoat. This relatively new type of paint is extremely
difficult to match when refinishing spot repairs.

Topcoat The final layer of paint applied to a substrate as in a

decorative or protective coating, or both, in the form of a
color coat (or basecoat) or a clearcoat, or both.

Transfer Efficiency Measurement, expressed as a percentage, of the amount

of paint deposited on a painted surface versus the
amount of paint lost to the surrounding environment in
the form of overspray.

Tri-coat Paint See Three-Stage

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Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Tukon A diamond shaped indentation is made with a Knoop

diamond indenter. The length of the long diagonal of the
diamond indentation is measured and converted to a
Knoop Hardness Number (KHN).

Two-stage Paint See basecoat/clearcoat.

Two-tone Painted with two different colors (versus monotone).

Undercoats All of the products used to prepare the surface to receive

color coats (primers, surfacers, putties, and sealers).

UV Stabilizers Chemicals added to the paint to absorb the ultraviolet

radiation present in the sunlight.

Varnish This is basically a paint without pigments.

Vehicle Viscosity A mixture of resins dissolved in suitable solvents with

various additives. The property of liquid which enables it
to resist flow.

Velocity Pressure The pressure resulting from a moving airstream, as

determined from pitot-tube readings, equivalent to the
total pressure less the static pressure.

Viscosity The resistance to flow. Usually measured by running a

given volume of liquid through a viscosity meter.

VOC Volatile Organic Compound – Usually the solvent content

of a paint.

Volatility The tendency of a liquid to evaporate.

Washer Crystal Particles caused by the crystallization of minerals,

additives, cleaners, or chemicals found in the water of
power washers.

Water-spotting Drops of water that mar the finish before it is thoroughly

cured.

Weathering The change of appearance of paint caused by exposure

to the elements.

Revised: 10/12/00 F-17

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix F – Glossary

Weight Per Gallon To determine the weight of one gallon of paint.

Weight Solids To determine the percent of solids in a given paint

sample.

Wet-on-wet Finish The technique of applying a fresh coat of paint over an

(WOW) earlier coat which has been allowed to “flash off” but not
cured. This technique minimizes difficulties with lifting or
overcuring of the first coat during cure of the second
coat.

Wetting Agent An aid to dispersion by addition of substances to lower

the surface tension of water.

Witness Plate A test coupon or other designated surface used to collect

samples of particulate matter deposited under the
influence of gravity for quantification and microscopical
analysis.

Wrap Around The phenomenon by which electrically charged paint

droplets curve around to the rear side of the object being
painted.

Wrinkling A paint defect in which the film surface skins over and
then absorbs liquid within the film. The absorption results
in swelling of the surface skin with the formation of
wrinkled texture.

Xylol (Xylene) A solvent of the aromatic hydrocarbon type. It is a

mixture of dimethyl benzenes, often used as a dilutant for
acrylic lacquers.

Revised: 10/12/00 F-18

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

APPENDIX G - CONTAMINATION IDENTIFICATION LIBRARY

This may look like a character
from a Godzilla movie, but it is
actually a fly that was pulled
from the clearcoat of a vehicle.

FIGURE1: Fly

There has been a lot of buzz

about this sort of contamination.
Simply being observant, and
getting rid of these pests before
they contaminate the vehicle is
the best form of prevention.

FIGURE 2: Bee

Revised: 09/07/00 G-1

 Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

A crater is a circular depression

found in the surface of paint
coatings. This troublesome
defect is caused by a physical
interaction between the paint
and contaminant. The low
surface tension of the
contaminant spreads radially
creating a circular area of low
surface tension material. The
paint flows away from the area
of low surface tension toward
the higher surface tension
region around the outer edges.

FIGURE 3: Soft & Dry Anti-perspirant” Crater

Aluminum Zirconium
Tetrachlorohydrex Gly,
Aluminum Chlorohydrate, and
Aluminum Chloride Basic do
not cause craters. It is possible
that they may act as a carrier
for the cratering agent, but
alone they do not disrupt the
surface tension of the paint.

FIGURE 4: Aluminum Zirconium Tetrachlorohydrex Gly

Revised: 09/07/00 G-2

 Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

This living organism was found

in the clearcoat of one of our
vehicles. This seven-legged
terror is being viewed under a
magnification of 500x.

FIGURE 5: Trichomes

A fly in the ointment, or in this

case the clearcoat. You must be
conscious of these little pests in
the paint area.

FIGURE 6: Fly

Revised: 09/07/00 G-3

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

Care and proper maintainance of

the ovens will prevent fibers from
getting into the topcoat.

FIGURE 7: Fiberglass Pulled From the Oven Wall

Synthetic can fibers often find

their way into the clearcoat.

FIGURE 8: Synthetic Fibers

Revised: 09/07/00 G-4

 Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

Approved headgear in the

paintshop is a must. Unapproved
material is more likely to create
contamination.

FIGURE 9: Fibers From Elastic Band on Hairnet

An example of just how

damaging contamination from
unapproved paintshop wear can
be.

FIGURE 10: Blue Fiber Under Base Coat

Revised: 09/07/00 G-5

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

Improper use of a Bootie,

(wearing a disposable more then
once), results in fibers being
released into the Paintshop.

FIGURE 11: Fibers From String Holding Elastic to Bootie

Tyvek coverall’s are not generally

suggested for paintshop use
because of the fiber contamination
they bring. See the Paint Engineering
approved list for an alternative.

FIGURE 12: Fibers From Thread on Tyvek Uniform

Revised: 09/07/00 G-6

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

Synthetic fibers can come from

just about anywhere.
Unapproved clothing and
disposable clothing worn more
then once, are the prime culprits.

FIGURE 13: Synthetic Fiber

Multiple defects and inclusions in

the vehicles finish.

FIGURE 14: Radiant Zone / Rust, Overspray, Synthetic Fiber

Revised: 09/07/00 G-7

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

Oven dirt gets into the basecoat

by simply flaking off the ovens
interior, and falling onto the
vehicle.

FIGURE 15: Oven Dirt Under Basecoat

Oven dirt like this can be

prevented by following a
reasonable maintenance and
cleaning schedule for the oven.

FIGURE 16: Oven Dirt

Revised: 09/07/00 G-8

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

Improper cleaning and paint

maintenance can result in a build
up that eventually produces
multi-layered paint chips.

FIGURE 17: Multi Colored Paint Chip

Paint chips are among the most

easily detectable and
preventable of contaminants.
Care and attention to procedure
can keep them from infecting the
cars finish.

FIGURE 18: Paint Chip on a Millipore Filter Media

Revised: 09/07/00 G-9

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

Paint chips are generally large

enough to be easily detected in
the vehicle finish.

FIGURE 19: Red Paint Chip

This multi-colored paint chip

could have been prevented by
simply cleaning the tool fixtures
on a regular basis.

FIGURE 20: Multi-colored

Revised: 09/07/00 G-10

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

Rust can be a problem for a

vehicle before it ever sees any
rain. Beware of flaking in the
oven.

FIGURE 21: Rust Flake From the Oven

Though almost invisible to the

human eye, this type of
contaminant can be a time bomb
in the automobiles finish, if not
detected, or prevented.

FIGURE 22: Clearcoat (Contamination Inside Overhead Bells) 100x

Revised: 09/07/00 G-11

 Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

The dirt on the filter should not be as

old as the plant itself. This filter
should have been changed long
before it allowed countless
contaminants to pass through to the
vehicle.

FIGURE 23: Dirty Wall Filter From E-coat Scuff Booth

This sanding residue is the by-

product of the sanding process, and
can be a nuisance if not properly
controlled.

FIGURE 24: Prime Sanding Residue

Revised: 09/07/00 G-12

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

Sealer contamination is among

the most common and
preventable of all defects.

FIGURE 25: Body Shop Sealer

This sealer defect could have

been prevented by simply wiping
it off in the prep booth, before
primer was applied.

FIGURE 26: Body Shop Sealer

Revised: 09/07/00 G-13

Paint Engineering
Paint Shop Contamination Control Guidelines Appendix G – Contamination Identification Library

This weld ball is residue from the

the welding process. Occasionally
they escape the filtration process
and wind up as a contaminant.

FIGURE 27: Weld Balls

Proper filtration and maintance

along with diligence will prevent
weld balls, such as this, from
contaminating a vehicle finish.

FIGURE 28: Single Weld Ball

Revised: 09/07/00 G-14