Supplier Crater Training and Prevention

NPA Coatings, Inc.

Supplier Crater Training and Prevention

Customer First Mentality

NPA recognizes that our suppliers play a key role in the quality of our products and the satisfaction of our customers. Open communication, defined expectations, and continuous improvement are the essential tools to a successful business relationship and a customer first mentality. Part of these key items are the understanding of customer quality concerns and the ability of every supplier to help prevent quality issues.

Supplier Crater Training and Prevention

Crater Definition:
Craters are a dish shaped deformation in a paint surface that may penetrate to the layer below the paint. They are typically 1-4mm in diameter. The reason for the formation of craters is the difference in surface tension between liquid paint and a contaminant.

Microscopic Picture of Crater

Supplier Crater Training and Prevention

Crater Definition:

Effects of Contaminant to Liquid Paint

These rendered cut-away views show three stages (from top to bottom) of the simulation of a crater developing: The paint layer begins flat, with a localized concentration of a contaminate (shown in red). A crater develops, which spreads outwards and increases in depth. Once the paint is dry, the film appears thinner and the shape of the crater is preserved in the paint. (The thickness of the film has been exaggerated here.)

Crater Impact

2009 Lexus RX TMMC Cambridge, Ontario

Customer:
Stop production ~ Cost = $10,000 / per minute Scrapped car bodies ~ $20,000 each Additional labor and repairs Dumping the coating system equals waste paint disposal cost.

Crater Impact
2009 Toyota Venza Mfg at NAMC Kentucky

NPA and Suppliers:

Additional labor and cost for replacement material Loss of customer confidence Loss of business

Strong Manufacturing Program

NPA Crater Prevention Activities

Crater Prevention Products:

Craters can be caused contamination of the paint by a particle (solid or liquid) of a low surface tension. Typical contaminates that may cause craters are oils, greases, certain types of O-rings, plastics, and rubber gaskets. Silicones and Teflon sealant compounds (liquid or solid) are contaminants that have the highest potential of causing craters.
Potential crater causing ingredient

Crater Prevention

Equipment:
Ensure all parts are silicone free Parts are disassembled and cleaned before use Ensure replacement parts such as Orings or gland seals are silicone free Ensure filter manufactures do not sew using silicone lubricated needles

Crater Prevention

Operators:
Review crater training and personal care product lists with all new employees, visitors, and contractors Ensure that personal care products are not listed on the NPA Banned Ingredient List Ensure garment cleaning does not use or contaminate clothing with silicone
NPA Coatings, Inc. Personal Care Product Banned Ingedient List

The chemicals listed below are proven to cause craters in NPA materials. Please make sure your person care products DO NOT contain these chemicals. Should you come into contact with such materials, ensure they are completely cleaned off your person and possessions prior to reporting for work.

Silicone Polydimethlysiloxane Dimethicone Dimethiconol Cyclomethicone Phenyltrimethicone Silicadimethylsilylate Microcrystaline Wax Paraffin Wax

Crater Examples
Drums - New glue used by sub-supplier to hold drum lid gaskets in place contained material that cause craters on several NPA products. Totes Teflon tape used on valve assembly of totes caused crater outbreak at two NAMCs. New totes Caustic residue was left inside new totes which caused craters when finished product was filled into them.

Process Change Request Notification of Supplier manufacturing process changes is a key element in crater prevention. We ask all suppliers to understand and utilize the NPA Process Change Request process to help avoid problems before they impact product quality.

THANK YOU!