fes inhouse paint inspection guideline suppliers
TRANSCRIPT
FES – Painting & Inspection Guidelines
CQ / FF / 003 dt 23. 01. 2012
FES – Painting & Inspection
guidelines
Page 1 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Scope:
This document is a Guideline covering the usage of recommended paint , painting process
for FES, process parameters of FES painting, Quality criteria of painted FES Inspection,
repair methodology of the paint defects & quality certification before dispatch to Ashok
Leyland.
Objective:
i. To guide the FES painting Suppliers to ensure the quality of painting in both appearance
as well as in corrosion protection performance of the FES supplied to Ashok Leyland.
1.0 Guidelines:
FES painting Suppliers of Ashok Leyland shall adhere to the following guidelines in the
usage of recommended process, paint, consumables, Inspection of painted vehicle, repair of
paint defects, testing of various parameters for measuring the short term & long term
properties of paint , monitoring , recording & preservation of the quality records.
1.1 FES & its child parts shall be painted using only the recommended paint & process
mentioned in the Annexure A. Supplier shall ensure the surface coating quality of FES child
parts to meet Ashok Leyland Surface protection requirements standard ALS 268.03.
FES Liquid painting supplier shall maintain adequate records of monitoring the process
parameters mentioned in Annexure A.1
1.2 FES shall be classified into the appearance zone mentioned in Annexure B.1.
Inspection of the Painted FES shall be carried out based on the zone wise quality criteria
mentioned in the Annexure B.2.
Inspection of the Paint Defects on FES shall be done based on the frequency given in
Annexure B.3.
1.3 Possible issues with paint mixing & its root causes shall be understood by the FES
painting supplier based on the guidelines given in the Annexure C & appropriate remedy
shall be taken to ensure paint quality.
FES – Painting & Inspection
guidelines
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REF: CQ / FF / 003
DATE: 23.01.2012
1.4 Possible root causes of the Paint defects shall be understood by the FES painting
supplier based on the guidelines mentioned in the Annexure D & appropriate preventive &
corrective action shall be taken to avoid recurrence.
1.5 Identified paint defects shall be rectified based on the repair guidelines given in the
Annexure D.1.
1.6 PU Touch up of certain paint defects shall be done based on the guidelines given in the
Annexure D.2.
1.7 FES painting supplier shall incorporate the best process of PU Touch up by
understanding the Do’s & Don’ts of the PU painting process given in Annexure D.3
1.8 FES painting supplier shall use only the recommended Tools & consumable mentioned
in the Annexure E for paint mixing, painting , repair & Touch up.
1.9 FES painting supplier shall confirm the receipt paint quality by doing receipt inspection
for all the parameters mentioned in Annexure F & own the responsibility of the quality of
paint used for FES painting. The supplier shall equip himself with the adequate Lab facility
for testing.
2.0 FES Inspection & defect rectification shall be recorded in the FES Painting Inspection
card (Refer Annexure G) for every FES dispatched to Ashok Leyland.
The Inspection cards shall be retained & preserved for a minimum period of 2 years from the
date of dispatch to Ashok Leyland.
FES – Painting & Inspection
guidelines
Page 3 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
FES Painting
Child parts
Paint raw material
Sheet Metal
Quality Approval
Repair
Inspection
SCOPE of Guideline
ALS 268.03
FES Painting Process:
OK
Not OK
OK
FES – Painting & Inspection
guidelines
Page 4 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Annexure A. Recommended Paint & process:
Part name Option 1 Option 2
Primer Top coat Primer Top coat
FES Skin Liquid Painting:
Primer (715633)
Liquid Painting:
Berger Body Bake
Enamel Golden
Brown (036432)
FOP & Side
grills
CED:
NIPA / APPG /
BASF
Liquid Painting:
QD Auto Enamel
S/G AL Black
(B31J26)
CED:
NIPA / APPG /
BASF
PP Powder Coating:
Akzo – JN195N /
JN103N /
Marpol - 99-01001 /
Jotun - 1027028 /
Berger – 312J26.
Bottom grill
CED:
NIPA / APPG /
BASF
Liquid Painting:
Berger Body Bake
Enamel Golden
Brown (036432)
Mud guard
Mud guard
Stay
Under body Liquid Painting:
Primer (715633)
Liquid Painting:
Berger Body Bake
Enamel Golden
Brown (036432)
Touch Up
PU paint:
B’Thane L/B UC
Golden Brown
(475432)
Thinner & additive used shall be based on the above Paint supplier recommendations.
Pretreatment Chemicals used shall be only from Henkel / NIPA / Chemetall rai / APPG.
Shade detail:
Shade Parameter
Golden Brown L : 46.889; a: 18.407; b: 27.291; c:32.918; H: 55.979
Matt Black RAL 9005
FES – Painting & Inspection
guidelines
Page 5 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Annexure A.1 - Recommended process parameters – FES Liquid painting:
Process parameter
Process Value Inspection Frequency
Coating
weight
Dicationic
phosphating > 3.5 gsm
Once/ Shift Tricationic
phosphating > 2.5 gsm
Layer wise
DFT
Primer 30 Once / shift
Top coat 20 Refer Annexure B.2
Baking EMT Curing Time above 130c : 30 min Every Month
Compressed
dry air spec
Dew point + 10 deg C @ 6 bar as per ISO 8573-1
(Class 6)
Every Month Dust content
Less than 0.1 microns & 0.1 mg/m3
concentration as per ISO 8573-1
(Class 6)
Oil content Less than 0.01 mg/m3 as per ISO
8573-1 (Class 1)
FES – Painting & Inspection
guidelines
Page 6 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Annexure B – Quality criteria of painted FES:
B.1 Classification of FES into Appearance zones.
Classification Parts covered
Zone 1 False Panel, Corner Panel, Embellisher, Bottom grill, Side
grill (LH/RH), FOP.
Zone 2 Foot step, Wing end step (LH / RH).
Zone 3 Floor , Rear Facia & Mud guard (LH/ RH) , Under body &
all other parts.
FES – Painting & Inspection
guidelines
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REF: CQ / FF / 003
DATE: 23.01.2012
Annexure B.2 - Zone wise acceptance criteria of most common paint defects:
1. DFT:
Description Zone - 1 / 2 / 3 – 13 points (Refer Annexure G – DFT measurement locations)
Flat surfaces 50µ ~ 120
Within 5 cm from
Corners / Edges 40 ~ 100
2. Gloss:
Description Zone - 1 / 2 / 3
Flat surfaces Golden Brown - Min 90 @ 60, Black – 50 ~ 60@ 60
Within 5 cm from
Corners / Edges Not applicable
Description Zone - 1 / 2 / 3
MEK Solvent rub test No peel off or discoloration
3. Paint film Under bake:
Description Zone 1 Zone 2 Zone 3
Visible at a distance
of 2m from surface Zero
Visible only on close
observation Zero Max 3mm Max 5mm
4. Paint Sag / rundown:
Description Zone – 1 / 2 / 3
Visible Not acceptable
5. Paint crack / Touch mark:
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guidelines
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REF: CQ / FF / 003
DATE: 23.01.2012
6. Paint Overspray:
7. Paint poor hiding:
8. Paint Crater / Pinhole (For every 100cm x 100 cm surface area):
Description Zone 1 Zone 2 Zone 3
Heavy roughness &
Color variation (Touch feel)
Not acceptable
Light roughness but
no color variation Not acceptable Not acceptable Acceptable
Description Zone 1 Zone 2 Zone 3
Primer is visible Not acceptable
Slight color
difference on close
observation
Not acceptable Acceptable
Size of defect Zone 1 Zone 2 Zone 3
Φ > 1mm Zero
Φ 0.5 ~ 1mm Zero Max 3 Max 5
Φ < 0.5mm Zero Max 5 Max 10
9. Dust / Contamination (For every 100cm x 100cm Surface area):
Size of defect Zone 1 Zone 2 Zone 3
Φ > 1mm Zero Max 5 Max 10
Φ 0.5 ~ 1mm Max 2 Max 10 Max 15
Φ < 0.5mm Max 5 Max 10 Max 15
Forms of Dust:
Lint; Sanding dust; Booth dust; Oven dust; paint dust; Contamination,etc.
Zone wise acceptance criteria of paint defects - Continued
FES – Painting & Inspection
guidelines
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REF: CQ / FF / 003
DATE: 23.01.2012
10. Orange Peel:
11. Color Mismatch:
Description Zone 1 Zone 2 Zone 3
Visible at a distance
of 2m from surface Not acceptable
Visible only on close
observation Not acceptable Acceptable
Description Zone 1 Zone 2 Zone 3
Visible at a distance
of 2m from surface Not acceptable Acceptable
Visible only on close
observation Not acceptable Acceptable
Instrumental Color
difference to std
panel
Delta E < 3.0 Delta E < 4.0
Instrumental Color
difference to adjacent
parts
Delta E < 1.0
12. Cross Hatch Adhesion:
Description Zone – 1 / 2 / 3
In a 10 x 10 square lattice of 2mm.
Exfoliation along straight line & square
broken more than 50%.
Not acceptable
13. Sanding Mark:
Description Zone 1 Zone 2 Zone 3
Substrate
Sanding mark Not acceptable Acceptable
Polishing sanding
mark Not acceptable Not applicable
Zone wise acceptance criteria of paint defects - Continued
FES – Painting & Inspection
guidelines
Page 10 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
14. Paint Wrinkling:
Description Zone 1 Zone 2 Zone 3
Visible at a distance
of 2m from surface Not acceptable
Visible only on close
observation
Description Zone 1 Zone 2 Zone 3
Visible at a distance
of 2m from surface Not acceptable Acceptable
Visible only on close
observation Not acceptable Acceptable
15. Paint Blistering:
Zone wise acceptance criteria of paint defects - Continued
Description Zone 1 Zone 2 Zone 3
Visible at a distance
of 2m from surface Not acceptable
Visible only on close
observation
16. White patches:
Other paint defects like Acid attack, Bird droppings, Bits, Bleaching, Bleeding,
Blooming , Blowing, Blushing, chalking, Fading, Fish eye, Water marks, etc. are
also not acceptable in any of the Zones & shall be rectified based on the paint
supplier recommendations.
FES – Painting & Inspection
guidelines
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REF: CQ / FF / 003
DATE: 23.01.2012
Annexure B.3 - Painted FES - Inspection Frequency :
S.No Check points Inspection Frequency by
FES supplier
1 DFT Every 4th FES.
2 Gloss Once / hr.
3 Paint Film under bake – Solvent rub Once / hr.
4 Paint Sag / Rundown
Every FES
5 Paint Crack / Touch mark
6 Paint Overspray
7 Paint poor hiding
8 Paint Crater / Pinhole
9 Dust / Contamination
10 Orange Peel
11 Color Mismatch
12 Cross Hatch adhesion Once / Shift
13 Sanding Mark
Every FES
13.1 Polishing Mark
14 Wrinkling
15 Blistering
16 White patches
Other Paint defects
FES – Painting & Inspection
guidelines
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REF: CQ / FF / 003
DATE: 23.01.2012
Annexure C - Most common paint mixing issues, possible root cause
& remedy:
Defect Possible root cause Remedy
1. Paint settling
Improper stirring
Paint shall be discarded
Long storage
High atmospheric temperature
Non compatible thinner, etc.
2. Gelling
Contaminated mixing tools
Paint shall be discarded
Non compatible thinner
Usage of Touch up paint more than Pot Life, etc.
3. Paint dissolution
Usage of Touch up paint more than Pot Life
Non compatible thinner
Usage of expired paint, etc.
4. Skin formation
Air entry into paint / hardener / thinner container Reject paint
High atmospheric temperature, etc.
5. Paint Air bubble
Improper paint mixing Ensure agitation
Non compatible thinner Modify thinner
Mixing of Compressed air direct in paint, etc. Stop practice
6. Paint dust / contamination
Improper filtration Re-filter & use
Improper agitation, etc.
FES – Painting & Inspection
guidelines
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REF: CQ / FF / 003
DATE: 23.01.2012
Annexure D : Most common Paint Defects & possible root causes:
Defect Possible root causes
1. Low DFT
Low viscosity
Booth air imbalance
Inadequate lighting, insufficient or cramped working space, inaccessibility of surfaces
Poor spraying technique, spray gun too far from surface, incorrect compressed air pressure, incorrect nozzle adjustment
Poor application Technique, etc.
2. Loss of Gloss - Haziness
High roughness of substrate
Inadequate or excessive dilution
Non- compatible thinner
Thin coating film
Slow evaporation of the solvent
Drying at High humidity (Above 90% RH)
Improper mixing
Solvent fumes or exhaust gases attacking the surface
Use of strong detergents or cleaners on a newly painted surface
Insufficient air circulation in booth, etc.
2.1. Touch up - Gloss variation
Improper Paint touch up without merging thinner
Localized polishing
Non compatible thinner, etc.
3. Paint under bake
Improper mixing of paint
Non compatible thinner
Low EMT, etc.
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guidelines
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REF: CQ / FF / 003
DATE: 23.01.2012
Defect Possible root causes
4. Running / Sagging
Incorrect viscosity of the paint
Air or surface temperature too low
Use of poor quality or incorrect thinner
Excess thickness of application, air pressure too low, fan width too narrow, spray gun too close to the surface or moving too slowly
Excessive dilution of the paint causing low viscosity
Painting over Smooth surface, etc.
5. Crack Poor paint mixing, Incompatible thinner, contaminated substrate, over baking, Expired paint life, etc.
6. Overspray
Booth air Imbalance
Non masking of the adjacent surface during Touch up
Compressed air pressure too high
Inadequate extraction or ventilation
Non removal of the Touch up overspray with thinner after baking, etc.
7. Poor hiding
Thin Top coat film
Inadequate lighting, insufficient or cramped working space, inaccessibility of surfaces
Poor Spraying Technique
Top coat not stirred before use, etc.
8. Pin Hole
Fast evaporating solvent
Poor flash off before drying
High baking temperature
Air Bubbles in the paint mixing
Immediate exposure to high temperature, etc.
Most common paint defects & Possible root causes: Continued
FES – Painting & Inspection
guidelines
Page 15 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Defect Possible root causes
8.1. Crater
Contamination (Oil/grease/ water,etc) of the substrate not removed before painting
Contaminated mixing tools or equipment
Silicone in the environment or on the surface of the substrate
Moisture / Oil / dust in the compressed dry air or booth air supply, etc.
9. Dust / Contamination
Poor cleaning of the substrate
Cloth, booth & Oven Contamination
Improper / No filtration of the paint
Poor agitation of the paint, etc.
10. Orange peel
Paint incorrectly mixed, wrong viscosity, poor quality or incorrect thinner
Poor spraying technique, spray gun too far from surface, incorrect compressed air pressure, incorrect nozzle adjustment
Poor atomization of the paint
Low or High paint film thickness
Incorrect ambient or surface temperature
Long or very short flash off time between coats, etc.
11. Color Mismatch
Improper mixing of the Top coat
Low DFT of the Top coat
Poor PU Touch up
Usage of NC based paint, yellowing epoxy & alkyd based paints for Touch up - Yellowing
Usage of unapproved paints, Over baking of paint, etc.
Most common paint defects & Possible root causes: Continued
FES – Painting & Inspection
guidelines
Page 16 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Defect Possible root causes
12. Adhesion failure
Contamination (Oil/grease/ water, etc.) of the substrate not removed before painting
Poor phosphating of the CR sheet (Improper substrate preparation)
Non compatibility between primer & Top coat
Non compatible thinner
Paint film under bake or over bake
Painting over smooth surface without sanding, etc.
13. Sanding Mark
Deep / Coarse sanding of the substrate
Wrong sanding disc & method
Low coating thickness, etc.
13.1 Polishing Mark
Polishing over Uncured paint surface
Excessive pressure applied in polishing
Coarse polishing paste
Polishing immediately on the hot surface from oven
Worn out Polishing head, etc.
14. Wrinkling
Painting over unset primer before flash off
No compatibility between primer & top coat
Excessive film thickness
Non compatible thinner
Prolonged drying time
Immediate exposure to high temperature, etc.
Most common paint defects & Possible root causes: Continued
FES – Painting & Inspection
guidelines
Page 17 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Defect Possible root causes
15. Blistering
Painting on a hot surface
Paining on contaminated surface
Non compatible thinner
Exposure to rain or moisture before paint curing
Moisture migration thru paint surface, etc
16. White patches
Moisture entrapment before painting
Exposure to moisture or contamination before paint curing
Non compatible thinner
Water contamination of paint , etc
Most common paint defects & Possible root causes: Continued
FES – Painting & Inspection
guidelines
Page 18 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Annexure D.1 : Guideline for rectification of most common Paint defects.
Defect Condition
Repair Methodology D
ry
san
di
ng
Wet
Sa
nd
ing
Air
Blo
w
Cle
anin
g
PU
To
uch
u
p
Mer
gin
g Th
inn
er
Ho
t ai
r b
low
/ IR
h
eat
Polis
hin
g
Bat
ch
chan
ge
Rep
ain
tin
g
Reb
akin
g
Scu
ff
Orb
ital
1.Low DFT
Full Body
Part
2.Gloss
Full Body haziness
Under curing
Touch up Paint
Poor Touch up
3. Paint Under bake
4.1 Sag
4.2 Run down
5. Crack / Touch Mark
6. Over spray
Body paint
Touch up
7. Poor Hiding
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REF: CQ / FF / 003
DATE: 23.01.2012
Defect
Possible general root Cause
Repair Methodology D
ry
San
din
g
Wet
Sa
nd
ing
Air
Blo
w
Cle
anin
g
PU
To
uch
up
Mer
gin
g Th
inn
er
Ho
t ai
r b
low
/ IR
h
eat
Polis
hin
g
Bat
ch
chan
ge
Rep
ain
tin
g
Re
bak
ing
Scu
ff
Orb
ital
8. Crater / pinhole
9. Dust
9.1 Contamination
10. Orange Peel
11. Color Mismatch
Body Paint
Body paint Under curing
Paint
Touch up Under curing
12. Adhesion Failure
Substrate / Poor PT
Etch prim
er
Under baking
Over baking
Etch prim
er
Guideline for rectification of most common Paint defects - Continued
FES – Painting & Inspection
guidelines
Page 20 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Defect
Possible general root Cause
Repair Methodology D
ry
San
din
g
Wet
San
din
g
Air
Blo
w
Cle
anin
g
PU
To
uch
up
Mer
gin
g Th
inn
er
Ho
t ai
r b
low
/ IR
hea
t
Polis
hin
g
Bat
ch c
han
ge
Rep
ain
tin
g
Re
bak
ing
Scu
ff
Orb
ital
13. Sanding Mark
Substrate
Polishing
14. Wrinkling
Local
Full body Option
15. Blisters
16. White patches
Refer Annexure D.2 for Guideline on PU Touch up.
Guideline for rectification of most common Paint defects - Continued
FES – Painting & Inspection
guidelines
Page 21 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
C.1 Paint Touch up – Process :
Step Process Purpose Photo
1 Substrate cleaning
Clean the dust, contamination, water, grease / oil or any other contamination – Clean dry cloth
2 Sanding To remove the contamination & prepare the substrate for paint adhesion.
3 Air Blow Remove the dust generated by sanding operation
4 Cleaning To remove the sticky dust particles using Tack rag.
5 Paint Touch up Defect rectification
6 Merging thinner application (Optional)
To merge the wet PU film with the Body paint
7 Drying Cure the paint film with Dryer
8 Wet Sanding To prepare the paint film smooth for polishing
9 Polishing To level out the gloss of the Touched up surface similar to non painted surface
Annexure D.2 - Guideline for PU Paint Touch Up:
FES – Painting & Inspection
guidelines
Page 22 of 28
REF: CQ / FF / 003
DATE: 23.01.2012
Description Do’s Don’ts
Painting Location Inside paint Touch up booth
In open yard or under shed without exhaust
Surface preparation
Water contamination
Clean the surface with air blow, Dry cloth, followed by IPA & dry cloth.
Without cleaning & paint over water contamination
Dust/ contamination
Clean the surface with air blow, dry cloth & paint
Without cleaning & paint over dust/ contamination
Grease / Oil contamination
Clean with a separate dry clear cloth
Without cleaning & paint over grease /oil
Sanding for better adhesion
Usage of appropriate sand paper as per defect
Usage of inappropriate sand paper
Cleaning cloth
Usage of dry, clean & white cloth
Usage of waste cloth
Separate cloths for Dry wipe, water & grease
Usage of same cloth for all types of cleaning
IPA dispensing Thru Solvent dispenser Direct from container
Logo / Emblem & other plastic components Masking & no overspray Painting over the surface
Air Compressor line, reservoir & filter element
Drain the water collected every shift
No draining of the collected water
Paint Mixing
Paint storage In ventilated storage room
Open yard or non-ventilated room
Location Inside booth or paint kitchen
In open yard or shed
Paint Mixing – Paint, Hardener & Thinner
As per paint supplier recommendation
As per operator decision
Paint Mixing container
Closed Container Open container
Annexure D.3: PU Paint Touch Up – Do’s & Don’ts:
FES – Painting & Inspection
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REF: CQ / FF / 003
DATE: 23.01.2012
Description Do’s Don’ts
Paint Mixing
Paint storage container
With agitator No agitator
Paint filtration Thru Filter material Thru cloth
Paint viscosity measurement
Check with Ford Cup B4 No checking
Paint storage after mixing
Maximum 4 hours More than 4 hours
Paint mixing record Maintain time log for every lot of paint mix up
No monitoring of paint mixing time
Paint application
Spray gun Conventional gun with 0.8mm/ 0.9mm Nozzle
Conventional gun with 1.2 mm Nozzle
Condition of Spray gun
No paint leakage from gun
Paint Leakage from gun
Spray gun air pressure
4 ~ 5 bar More than 5 bar
Spray gun distance from surface
25 ~ 35cm Spray from long or short distance
Paint overspray Clean with Solvent No cleaning
Painted vehicle exposure to open atmosphere
After baking & polishing After painting without baking
De masking Removal of the masks after painting
No removal of mask & send to dispatch
Safety of workers Wear PPE Not wearing PPE
PU Paint Touch Up – Do’s & Don’ts : Continued
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REF: CQ / FF / 003
DATE: 23.01.2012
Annexure E - Recommended Tools & Consumables for painting
& repair of paint defects:
Operation Tools & Consumable
Paint Mixing Ford Cup B4
Measuring jar & scale
Dry Scuff Sanding P 600 grit sandpaper – Cut / round
Round Sanding pad
Dry Orbital Sanding P 400 grit sandpaper - round
Orbital sander
Air Blow Air gun
Dry sanding – Wiping Tack rag
White, Clean & Lint free cloth
Wet Sanding P 2000 grit sandpaper
Sanding block
Wet sanding - Wiping White, Clean & Lint free cloth
Paint Spray gun
Booth Conventional / HVLP / Electrostatic gun with 1.2mm Nozzle
Touch up Conventional / HVLP gun with 0.8 mm/ 0.9mm Nozzle
Touch up paint Drying Hot air Blower / Infra Red Lamp
Polishing
2500 rpm Polishing Tool
Polishing pad with 3” / 5” / 12’’ wool
Paste Glaze (3M)
* Required facility for FES painting, repair & Touch up process shall be captured in the
process & facility audit of Ashok Leyland – CQ Team.
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REF: CQ / FF / 003
DATE: 23.01.2012
Annexure F – Inspection parameters for every Paint batch (Primer / Topcoat):
Parameter Criteria Remarks
Solvent rub test (30% Toluene
& 70% Iso Octane)
No discoloration & surface alterations –
20 Double rubs
Self
Inspection by
FES Painting
supplier
Pencil hardness min HB
Cross cut adhesion
In a 10 x 10 square lattice of 2mm.
- No exfoliation along a straight line.
- No square broken up to 50% of the
area.
Scratch hardness Min 3000g
Impact resistance (ball dia – ½”,
Weight – 500g
Height – 50 cm)
No film crack & exfoliation.
Visual color difference Same as reference panel
Gloss @ 60 Refer Annexure B.2
Gloss o
meter or
Paint Test
certificate
Acid resistance (0.1n H2So4
soln.) – 20±2ºc / 8h
No surface defect on the film after
washing with DM water
Paint
manufacturer
Test
certificate
Alkali resistance (0.1n NaOH
soln.) – 20±2ºc / 8h
No surface defect on the film after
washing with DM water
Erichsen cupping No cracks up to 5mm indentation.
Resistance to UV light
alternating with humidity (200
hrs.) - Irradiance: 0.47 w/m2/nm
- Chalking & film cracking not
allowed.
- Gloss variation 15%
- No color variations are allowed.
Resistance to humidity
(500hrs @ 40±2°c – 95% ~
100% RH)
No film removal and blistering are
allowed. Min 80% of adhesion should be
retained
Water resistance
(40ºc / 240hrs)
No surface defect on the film. shall pass
adhesion at 2mm square
Corrosion resistance
(300 hrs. for CR Panel /
components) As per ASTM
B117 – Min 500 hrs. for CED
coated components
Edge masked and damage free
component, the following are not
allowed:
- Corrosion focuses on weld
junctions and surfaces in general
- Blistering.
Under pellicular corrosion ≤2mm
Submit
samples on
Line
condition &
get it tested
from Paint
manufacturer
Please refer Surface protection requirements standard ALS 268.03 for testing Methods.
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DATE: 23.01.2012
1 3 2
4 5
13
12
8
7
11
Annexure F.1 - DFT Inspection Template:
9
10
6
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DATE: 23.01.2012
Annexure G - FES Inspection Card:
1, Sardar Patel Road, Guindy, Chennai – 600 032.
VISION
To be among Global Top 10 in Trucks & Top 5 in buses.
QUALITY POLICY
Ashok Leyland is committed to achieve customer satisfaction, by anticipating
and delivering superior value to the customers in relation to their own business,
through the products and services offered by the Company and comply with
statutory requirements.
Towards this, the Quality Policy of Ashok Leyland is to make continual
improvements in the processes that constitute the quality management system,
to make them more robust and to enhance their effectiveness and efficiency in
achieving stated objectives, leading to:
• Superior products manufactured as also services offered by the Company.
• Maximum use of employee potential to contribute to quality and
environment, by progressive up gradation of their knowledge and skills as
appropriate to their functions.
• Seamless involvement from vendors and dealers in the mission of the
Company to address customers’ changing needs and protection of the
environment.
Managing Director January, 2007
1, Sardar Patel Road, Guindy, Chennai – 600 032.