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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Type of characteristic No. 1:
Offset
No. 2:
Burn marks
No. 3:
Dents
Page
Appendix to VDA Volume 16 2nd revised edition, 2008
Type of characteristic No. 28: Various polishing defects
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No. 28a: Stippling No. 28b: Dull areas
No. 4a: Bubbles
No. 28c: Holograms
No. 4b: Pitting
No. 28d: Polishing flecks
No. 5:
Impression marks
No. 6:
Anodising splits
No. 30: Polishing streaks
No. 7:
Colour misting
No. 31: Pores
No. 8:
Colour differences
No. 32: Indications of seams / seam-welds
No. 9:
Swollen edges
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No. 29: Polishing "fish" / "comet tails"
No. 33: Scour marks
No. 10: Flecks
No. 34: Step marks (linear traces of rolling)
No. 11: Flash on tool split line
No. 35: Striations
No. 12: Differences in sheen
No. 36: Graininess
No. 13: Flash / burrs
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No. 37: Corrugations
No. 14: Grittiness
No. 38a: Cloudiness/ fogging/ streaks
No. 15: Hairline splits
No. 38b: Streaks caused by moisture / air
No. 16: Contact / gripping points
No. 39: Differences in coating thicknesses
No. 17: Scratches; grooves
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No. 40: Sink marks
No. 18: Paint runs
No. 41: Converging flow marks
No. 19: Lens-like paint marks
No. 42: Sucker marks
No. 20: Thin coating areas
No. 43: Seam welds
No. 21: Macro-splits
14
No. 44: Moisture inclusions
No. 22: Pin-holes
No. 45: Holes
No. 23: Nickel patches
No. 46: Alignment gap / offset
No. 24: "Orange-peel" effect
No. 47: Patch marks
No. 25: Oxide lines
15
No. 26: Pimpling / inclusions
1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
No. 27: Pigmentation problems
No. 48: Jagged knife edges No. 49: Differences in structure and texture
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
No. 50: Compressed folds
16
No. 51: Paint residues No. 52: Burn marks
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Page 1 of 17
16
Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 1: Offset Data: Definition: Misalignment where parts are structured (for example, by vulcanisation or over-moulding). Process allocation: 5, 8, 12, 13, 15 Examples of permissible characteristic features: Zone A: Visible and detectable by touch +/- 0.3 mm Zone B: +/- 0.7 mm
No. 2: Burn marks Data: Definition: Matt / crumbly appearance to surface, caused by dendritic separation in the limit current area (referred to as "buds" when they are large). Process allocation: 1, 6 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 3: Dents Data: Definition: Flat bubble-like depressions, caused by high pressure. Process allocation: 6, 8 -16 Examples of permissible characteristic features: Zone A: Not acceptable if visible at a distance of > 800 mm Zone B: Not acceptable if visible at a distance of > 1200 mm
No. 4a: Bubbles Data: Definition: Generally round, even protrusions (hollow inside). Process allocation: 2, 3, 6, 7, 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 4b: Pitting Data: Definition: Generally circular, crater-like depressions in the top coat or intermediate coats. Typified by raised edges. Process allocation: 2, 3, 6, 7, 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 5: Impression marks Data: Definition: Irregularly distributed, slight spots or depressions to the surface, over very limited areas, caused by the compression of foreign bodies. Process allocation: 6, 8, 9, 10, 12, 13, 16 Examples of permissible characteristic features: Zone A: D = 0.7 mm max. 2 depressions within a spacing of 400 mm Zone B: D = 1.0 mm max. 4 depressions within a spacing of 300 mm
No. 6: Anodising splits Data: Definition: Micro-splits : small, linear features in the anodising coating, caused by excessive local deformation of the component or excessive coating build-up during anodizing. Process allocation: 1 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 7: Colour misting Data: Definition: Fine, dust-like paint particles on the surface, not distributed in a homogenous manner in the paint film; drop-like paint particles distributed over the paint film. Process allocation: 3, 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Acceptable
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 8: Colour differences Data: Definition: Colour deviation on a surface by comparison with the neighbouring surface or reference sample. This results from : (a) materials (b) process (c) subjective impression : saturation; brightness; purity; level of sheen; depth; surface structure.
Process allocation: 2, 3, 6, 13 Examples of permissible characteristic features: Zone A: Deviation refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 9: Swollen edges Data: Definition: A thickening of paint coatings (bulging) on edges of components, such as are caused by surface tensions. The effect correlates primarily with the edge radius and/or the position of the component during the process. Process allocation: 2, 3, 6, 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Acceptable
No. 10: Flecks Data: Definition: Sharply delineated, local dulling of the surface, caused for example, by dirt / corrosion in spots or larger areas, or drying flecks. Process allocation: 1, 2, 3, 6, 7, 13 Examples of permissible characteristic features: Zone A: Not acceptable Zone B: Not acceptable
No. 11: Flash on tool split line Data: Definition: Flash which can occur where there is a mismatch between parts of a tool or sliders (e.g., plastic residues on injection-moulded parts). Can also be caused by wear and overflows. Process allocation: 5, 6, 13 Examples of permissible characteristic features: Zone A: Max. +0.3 mm Zone B: Max. +0.5 mm
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 12: Differences in sheen Data: Definition: The sheen (or gloss) differs from that of the (master) sample or specification figure on some areas or over complete surfaces. Process allocation: 1, 3, 6, 7, 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 13: Flash / burrs Data: Definition: Sharp-edged projection of edge zones from earlier process (e.g., stamping burrs on cut edges; flash on plastic mouldings; paint grit). Process allocation: 2, 3, 5, 8, 15 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 14: Grittiness Data: Definition: Visual (optical) effect which can occur by diffuse reflection on interfaces between different structures (e.g., etched granularity). Process allocation: 1, 3, 6 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 15: Hairline splits Data: Definition: Extremely fine lines of damage. Process allocation: 3, 6, 10, 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 16: Contact / gripping points Data: Definition: Small areas, usually as spots where paint / coating is missing (in an area not normally visible), caused by suspension clamps, contact with painting frames, etc.). Process allocation: 1, 2, 6, 7 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 17: Scratches; grooves Data: Definition: Lines of damage, caused by inappropriate handling.(e.g., when removing parts from the tool). Process allocation: 5, 6, 8, 10, 13, 16 Examples of permissible characteristic features (longitudinal): Zone A: L < 4mm, W < 0,5mm Max. 2 scratches within 300 mm Zone B: L < 10mm, W < 0,7mm Max. 4 scratches within 200 mm Examples of permissible characteristic features (transverse): Zone A: Not acceptable Zone B: Not acceptable
No. 18: Paint runs Data: Definition: Tracks of paint in the top coat or in an undercoat, on vertical surfaces (generally in the vicinity of grooves, rounded sections, folds or piercings). Process allocation: 2, 3, 13 Examples of permissible characteristic features: Zone A: Not acceptable Zone B: Acceptable
No. 19: Lens-like paint marks Data: Definition: Distortion in paint surface which can be seen but not felt: paint runs / streaks in the early stages. Process allocation: 2, 3, 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 20: Thin coating areas Data: Definition: Inadequate top coating (the substrate can be seen through the surface coating) Process allocation: 2, 3, 7, 13 Examples of permissible characteristic features: Zone A: Not acceptable Zone B: Refer to MTP sample(s)
No. 21: Macro-splits Data: Definition: Splits in the galvanic coating, caused by deformation or stresses in the component. Process allocation: 1, 6 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 22: Pin-holes Data: Definition: Very small cratering (see No. 4b); also micro-pores. Process allocation: 2, 3, 6, 7, 13 Examples of permissible characteristic features: Zone A: A frequency of max. 5 pin-holes 2 over 4 cm permitted Zone B: Pin-holes permitted
No. 23: Nickel patches Data: Definition: Yellowish places in the contact area and in areas where the current density is low. Process allocation: 6 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 24: "Orange-peel" effect Data: Definition: A rough or wave-like appearance of a painted surface which may contain a texture; a grained paint finish with the structure of an orange peel. Process allocation: 2, 3, 6, 13 Examples of permissible characteristic features: Zone A: A fine structure is permitted – refer to limit sample for severity and surface area. Zone B: A coarse structure is permitted – refer to limit sample for severity and surface area.
No. 25: Oxide lines Data: Definition: Identification : Streaks caused by oxide inclusions and/or oxide lines. Description & effects : Pencil-like, white or grey lines in the direction in which the part was formed. The degree of visibility depends on the type and quantity of oxide inclusions. Process allocation: 11 Examples of permissible characteristic features: Zone A: Not permitted if structures visible at a distance of > 800 mm. Zone B: Not permitted if structures visible at a distance of > 1200 mm.
No. 26: Pimpling / inclusions Data: Definition: Contamination within the surface, such as dust or fluff, which protrudes in some areas through the coating or growths causing problems in the build-up of coats. Process allocation: 1 -7, 15 Examples of permissible characteristic features: Zone A: See Section 10.2 Zone B: See Section 10.2
No. 27: Pigmentation problems Data: Definition: Disorientation of pigments (e.g., metal flakes). Process allocation: 2, 3 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s)
No illustration available
Zone B: Refer to MTP sample(s)
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 28: Various polishing defects Data: Definition: Collective category for defects not often encountered / which form a small percentage of defects Stippling:
Polygonal, flecked areas caused by material residues which have been polished in.
Dull areas: These occur following electrolytic sheening and are caused by excessive local heating; also surfaces areas which have not been sufficiently polished. Holograms: Polishing defects with a 3-dimensional effect. These occur particularly with dark paint colours. Polishing flecks: Restricted circular areas with a much smoother surface than the surroundings
Process allocation: 6, 9, 13, 16 Examples of permissible characteristic features: Zone A: Not permitted if visible at a distance of > 800 mm. Zone B: Not permitted if visible at a distance of > 1200 mm.
No. 28a: Stippling Data: Definition: Polygonal, flecked areas caused by material residues which have been polished in. Process allocation: Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) No illustration available
Zone B: Refer to MTP sample(s)
No. 28b: Dull areas Data: Definition: These occur following electrolytic sheening and are caused by excessive local heating; also surfaces areas which have not been sufficiently polished. Process allocation: Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 28c: Holograms Data: Definition: Polishing defects with a 3-dimensional effect. These occur particularly with dark paint colours. Process allocation: Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) No illustration available
Zone B: Refer to MTP sample(s)
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 28d: Polishing flecks Data: Definition: Restricted circular areas with a much smoother surface than the surroundings. Process allocation: Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 29: Polishing "fish" / "comet tails" Data: Definition: Depressions in a shape similar to that of a fish, caused during the polishing process by a foreign body, a pore or other pre-conditioning from earlier processes, such as grinding. Process allocation: 6, 9, 11, 13 Examples of permissible characteristic features: Zone A: D < 0.3 mm, W < 2.5 mm, L < 5 mm Max. 2 within a spacing of 400 mm Zone B: D < 0.5 mm, W < 3 mm, L < 8 mm Max. 4 within a spacing of 300 mm
No. 30: Polishing streaks Data: Definition: Very fine, localised raising of visible ribs, caused by the polishing process (incorrect polishing paste and / or disc was used). Process allocation: 6, 9, 13, 16 Examples of permissible characteristic features: Zone A: L < 60 mm, B < 0.5 mm, Max. 6 within a spacing of 300 mm Zone B: L < 80 mm, B < 3 mm, Max. 10 within a spacing of 200 mm
No. 31: Pores Data: Definition: Small holes, visible with the naked eye, in the top coating, which may penetrate to the base material in places. Process allocation: 2, 3, 6, 13, 15 Examples of permissible characteristic features: Zone A: See Section 10.2 Zone B: See Section 10.2
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 32: Indications of seams / seam-welds Data: Definition: Identification: Traces of longitudinal seams (extrusion press marks) Traces of weld areas. Description & effects: Traces of (narrow) streaks, running in the direction in which the part was formed, where the area is seen as lighter or darker than the surrounding material, depending on lighting conditions. They can also occur in association with sink-marks or step-marks. Indications of longitudinal seam / seam-welds are caused by manufacturing processes and are unavoidable; however, the level of their appearance can be influenced.
No illustration available
Process allocation: 4, 8 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 33: Scour marks Data: Definition: Flat, local roughing of the surface, generally seen as differences in levels of sheen. Process allocation: 6, 10, 13, 15 Examples of permissible characteristic features: Zone A: Not acceptable Zone B: Refer to MTP sample(s)
No. 34: Step marks (linear traces of rolling) Data: Definition: Stripes, running parallel to the direction of the pressing / extrusion, over the length of the profile, generally in the form of “steps“ , which are especially visible after a coating process. Process allocation: 4, 6, 8, 15 No illustration available
Examples of permissible characteristic features: Zone A: Not acceptable if visible at > 800 mm. Zone B: Not acceptable if visible at > 1200 mm.
No. 35: Striations Data: Definition: Liquation streaks with an electro-potentiostatic effect, caused by pre-treatment for anodising and resulting from liquation in the incoming material Process allocation: 8, 11 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s) Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 36: Graininess Data: Definition: Slight graininess of a galvanised surface; comparable with the "orange peel" appearance on painted surfaces Process allocation: 6 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 37: Corrugations Data: Definition: Wave-like, parallel marks on the surface of the panel or profile, at an angle to the direction of rolling or compression, which can be seen in special observation positions (e.g., looking in the rear-view mirror, reflection in a longitudinal direction at a very shallow angle of observation).
Process allocation: 6, 8, 9, 11, 13, 16 Examples of permissible characteristic features: Zone A: Not permitted when checked under the following conditions :
● component in its "installed" position ● artificial light-source 1.2 m over the component ● checked at 2.5 m ± 0.5 m from the component ● direction of observation is at 20°-45° to the longitudinal axis of the vehicle with static observation
Zone B: Not permitted if visible at > 4 m when evaluated as described for Zone A
No. 38a: Cloudiness/ fogging/ streaks Data: Definition: When polishing: local areas which are matt, dull, cloudy or
streaky, with diffuse transfer between different areas (process allocation 9). When painting: noticeable, partially light or dark areas within a (metallic) paint finish with diffuse transfer from one area to the next (process allocation 3). Dull areas within the overall surface; with diffuse transfer from one area to the next Process allocation 6, 7)
Process allocation: 3, 6, 7, 9, 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 38b: Streaks caused by moisture / air Data: Definition: These occur during plastic injection moulding and are caused by moisture in the plastic or air inclusions during the injection moulding process. Process allocation: 9, 12 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s) Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 39: Differences in coating thicknesses Data: Definition: These occur during galvanizing as a result of inappropriate current density distribution (process allocation 6) or in other processes because of different particulate flows / flow angles or separation conditions. Process allocation: 2, 3, 6 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 40: Sink marks Data: Definition: Visible dents in the surface, caused by elements on the other side of the component, such as ribs, steps and domes (process allocation 6). Dents in the surface, caused by inappropriate component geometry and / or shrinkage (process allocation 12). Process allocation: 6, 12, 13, 15 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 41: Converging flow marks Data: Definition: Visible scratch-like flow-marks on plastic parts where flow fronts converge. Process allocation: 6, 13, 15 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 42: Sucker marks Data: Definition: The result of contact between the surface and rubber suckers. They are visible marks, caused by sucker deposits when removing the part following the process. Process allocation: 3, 6, 12, 15, 16 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 43: Seam welds Data: Definition: These occur at the convergence of two mass flows after piercings and domes (converging seam welds). Process allocation: 12, 13, 15 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) No illustration available
Zone B: Refer to MTP sample(s)
No. 44: Moisture inclusions Data: Definition: Damp material, caused by incorrect preparation of the material. Expanding moisture is deposited as streaks or bubbles on the surface of the article. Process allocation: 2, 5, 12, 13 Examples of permissible characteristic features: Zone A: Not acceptable
No illustration available
Zone B: Refer to MTP sample(s) Acceptable
No. 45: Holes Data: Definition: Holes in the surface coating, visible with the naked eye, penetrating to the base material. Process allocation: 6 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Refer to MTP sample(s)
No. 46: Alignment gap / offset Data: Definition: Alignment gap : Caused by inaccurate alignment of veneers / a line is visible. Alignment offset : Caused by inaccurate alignment of veneer / an offset in structural symmetry Process allocation: 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Acceptable
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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16
Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 47: Patch marks Data: Definition: Caused by voids, holes and splits. Process allocation: 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Acceptable
No. 48: Jagged knife edges Data: Definition: Damage caused by a knife when peeling / deburring the component. Process allocation: 13 Examples of permissible characteristic features: Zone A: Not acceptable Zone B: Refer to MTP sample(s)
No. 49: Differences in structure and texture Data: Definition: Uneven structure. Branches and bars not adequately formed. This occurs in nature. Process allocation: 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Acceptable
No. 50: Compressed folds Data: Definition: Visible lines; overlapping materials. Process allocation: 13 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) Zone B: Acceptable
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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16
Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
No. 51: Paint residues Data: Definition: Parts of the surface have not been removed by the laser process. Process allocation: 17 Examples of permissible characteristic features: Zone A: Not acceptable No illustration available
Zone B: Refer to MTP sample(s)
No. 52: Burn marks Data: Definition: Thermal changes in the plastic substrate (changes in colour). Process allocation: 5, 17 Examples of permissible characteristic features: Zone A: Refer to MTP sample(s) No illustration available
Zone B: Refer to MTP sample(s)
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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16
Decorative Surface of Attachment & Functional Parts to the Exterior and Interior of Automobiles
Appendix to VDA Volume 16 2nd revised edition, 2008
Imprint
The entire contents of these pages are protected by copyright. Responsible for contents:
VDA QMC Qualitäts Management Center im Verband der Automobilindustrie VDA QMC An den Drei Hasen 31 D-61440 Oberursel GERMANY Phone: Fax: E-Mail: Web:
+49 (0)6171 / 9122-0 +49 (0)6171 / 9122-14
[email protected] www.vda-qmc.de
In spite of great care mistakes can not be completely ruled out. In the case of differing information please consider the printed VDA Volume 16 as correct.
Version 1.0
Source Legend: 1) Anodizing 2) Powder coating (EPS) 3) Wet painting 4) Extrusion 5) Injection moulding 6) Galvanizing
7) Plasma process (evaporation, sputter, CVD, PVD) 8) Over-moulding 9) Polishing 10) Assembly / packaging / handling 11) Incoming material 12) Plastic processing
13) Refined wood surfaces 14) Application technology (gluing insert foils, embossing decorative foils) 15) Metal die-casting 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.) 17) Laser lettering
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Attribute Gage R & R Effectiveness Instructions: 1) 2)
3)
4)
5) 6) 7) 8)
The following spreadsheet is used to calculate an Attribute GR&R Effectiveness, in which up to 100 samples can be evaluated, using 2 or 3 operators. In the Data Entry worksheet fill in the appropriate information in the Scoring Report section and enter the type of Attributes you are evaluating in the Attribute Legend section. YOU MUST ENTER THE INFORMATION IN THE ATTRIBUTE LEGEND SECTION OR THE SPREADSHEET WILL NOT WORK. The attributes can be either alpha or numeric, e.g. Yes, No; pass, fail; go, stop; or 1, 2. You must be consistent throughout the form and spell properly. If you or an expert has selected samples to be evaluated and you know what attributes these samples are, enter this information in the Attribute sample column. This will enable you to determine how well each operator can evaluate a set of samples against a known standard. You do not need to enter information in this column for the spreadsheet to work although you will not be able to assess the operators against known standards. You do not have to specify how many operators or the # of samples that you will be evaluating during the test. Simply enter the data into the spreadsheet under the specific operator. Remember the attributes must be spelled properly or the spreadsheet will not analyze the data correctly. To print a copy of the report click on the Print Report icon. To delete the data in the spreadsheet, click on the Delete Data icon. To delete all and begin a new test, click on the Delete All icon To see a Demo of the Attribute GR&R Effectiveness spreadsheet, click on the Demo icon. Move around the spread sheet to see the data. When you are finished click the Delete All icon to delete all data to begin entering your own data.
The 95% UCL and 95% LCL represent the 95% upper and lower confidence limits on the binomial distribution. The Calculated Score is the basic computation reported on the report page for % Appraiser and % Score vs Attribute. The 95% confidence interval represents the range within which the true Calculated Score lies given the uncertainty associated with limited sample sizes. As sample size increases (in this case, Total Inspected) the confidence interval will get smaller and smaller which indicates more reliable estimates of the true percentages. In the case of the Demo data, the true Calculated score for Operator 1 could be as low as 76.8% given that only 14 samples inspected, even though there was a 100% Appraiser value calculated. Also, even though Operator 2 had a lower score, Operators 1 and 3 cannot be distinguished from Operator 2 because the calculated score of #2 (78.6%) lies within the confidence limits for Operators 1 and 3. With a worksheet limitation of 100 samples, at best a lower 95% limit of 96.4% can be calculated. Thus, we would have to say that an inspector could be as bad as 96% efficient, even though he/she missed no calls. Sample Size # Matches 95% UCL Calculated Score 95% LCL
30 30 100,0% 100,0% 88,4%
< Try out different combinations of number of samples and number of matches < to see the effects of sample size. In this case, a sample size of 30 with < one non-match will yield a 17% confidence interval. In order to get reasonable < reliability in estimates of efficiency, large sample sizes will be required.
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Data Entry
Attribute Gage R & R Effectiveness SCORING REPORT 5
Attribute Legend
(used in computations)
1 Pass 2 Fail
Known Population Sample # Attribute 1 Pass 2 Pass 3 Pass 4 Pass 5 Fail 6 Fail 7 Pass 8 Pass 9 Fail 10 Pass 11 Pass 12 Pass 13 Pass 14 Pass 15 Fail 16 Pass 17 Pass 18 Pass 19 Fail 20 Pass 21 Pass 22 Pass 23 Pass 24 Pass 25 Fail 26 Pass 27 Pass 28 Pass 29 Fail 30 Pass 31 99 100
Operator #1 Try #1 Try #2 Pass Pass Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass
% APPRAISER SCORE(1) -> % SCORE VS. ATTRIBUTE
(2)
->
DATE: NAME: PRODUCT: BUSINESS:
04.01.2001 Acme Employee Widgets
All operators
Earth Products
Operator #2 Try #1 Try #2 Pass Pass Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass
Operator #3 Try #1 Try #2 Pass Pass Pass Pass Pass Pass Fail Pass Pass Fail Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Pass Pass Fail Pass Pass Fail Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass Pass Pass Pass Pass Pass Pass Fail Pass Fail Fail Pass Pass Pass Pass Pass Pass Fail Fail Pass Pass
100,00%
100,00%
83,33%
93,33%
96,67%
80,00%
SCREEN % EFFECTIVE SCORE(3) ->
agree within and
All Operators
between each
agree with
Other
standard
Y/N Agree Y Y Y N N Y Y Y Y Y Y Y Y N N Y Y Y Y Y Y N Y N Y Y Y Y Y Y
Y/N Agree Y Y Y N N N Y Y Y Y Y Y Y N N Y Y Y Y Y Y N Y N Y Y Y Y Y Y
80,00%
SCREEN % EFFECTIVE SCORE vs. ATTRIBUTE
(4)
->
76,67%
Note: Operator agrees with him/herself on both trials Operator agrees on both trials with the known standard (3) All operators agreed within and between themselves (4) All operators agreed within and between themselves AND agreed with the known standard (5) Enter Pass/Fail, Good/Bad, Accept/Reject or other labels which indicate status of inspection (1) (2)
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Report Attribute Gage R & R Effectiveness SCORING REPORT DATE: NAME: PRODUCT: BUSINESS:
Attribute Legend 1 Pass 2 Fail Known Population Sample # Attribute 1 Pass 2 Pass 3 Pass 4 Pass 5 Fail 6 Fail 7 Pass 8 Pass 9 Fail 10 Pass 11 Pass 12 Pass 13 Pass 14 Pass 15 Fail 16 Pass 17 Pass 18 Pass 19 Fail 20 Pass 21 Pass 22 Pass 23 Pass 24 Pass 25 Fail 26 Pass 27 Pass 28 Pass 29 Fail 30 Pass 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 -
Operator #1 Try #1 Try #2
04.01.2001 Acme Employee Widgets Earth Products
Operator #2 Try #1 Try #2
All operators agree within and All Operators between each agree with Other standard
Operator #3 Try #1 Try #2
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Fail
Pass
Fail
Fail
Fail
Fail
Pass
Fail
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Fail
Fail
Fail
Fail
Fail
Fail
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Fail
Pass
Fail
Fail
Fail
Fail
Pass
Fail
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Fail
Fail
Fail
Fail
Fail
Fail
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Fail
Fail
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Fail
Pass
Fail
Fail
Fail
Fail
Fail
Fail
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Fail
Fail
Fail
Fail
Fail
Fail
Pass
Pass
Pass
Pass
Pass
Pass
-
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% APPRAISER SCORE(1) -> % SCORE VS. ATTRIBUTE(2) ->
100,00% 93,33%
100,00% 96,67%
Y/N Agree Y Y Y N N Y Y Y Y Y Y Y Y N N Y Y Y Y Y Y N Y N Y Y Y Y Y Y
Y/N Agree Y Y Y N N N Y Y Y Y Y Y Y N N Y Y Y Y Y Y N Y N Y Y Y Y Y Y
-
83,33% 80,00%
SCREEN % EFFECTIVE SCORE(3) -> 80,00% SCREEN % EFFECTIVE SCORE vs. ATTRIBUTE(4) -> 76,67% Note: (1) (2) (3) (4) (5)
Operator agrees with him/herself on both trials Operator agrees on both trials with the known standard All operators agreed within and between themselves All operators agreed within and between themselves AND agreed with the known standard Enter Pass/Fail, Good/Bad, Accept/Reject or other labels which indicate status of inspection
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Statistical Report - Attribute Gage R&R Study DATE: NAME: PRODUCT: BUSINESS:
04.01.2001 Acme Employee Widgets Earth Products
% Appraiser1 Operator #1 Operator #2 Operator #3 30 30 30 30 30 25
Source Total Inspected # Matched False Negative (operator rejected good product) False Positive (operator accepted bad product) Mixed 95% UCL 100,0% 100,0% Calculated Score 100,0% 100,0% 95% LCL 88,4% 88,4%
Screen % Effective Score3 30 24
Total Inspected # in Agreement 95% UCL Calculated Score 95% LCL
1 1 0 99,2% 93,3% 77,9%
95% UCL Calculated Score 95% LCL
110,0%
110,0% 90,0%
80,0%
80,0%
70,0%
70,0%
% Efficiency
100,0%
40,0%
60,0% 50,0% 40,0%
30,0%
30,0%
20,0%
20,0%
10,0%
10,0%
0,0%
95% UCL Calculated Score 95% LCL
% Score vs Appraiser
90,0%
50,0%
0 1 5 92,3% 80,0% 61,4%
90,1% 76,7% 57,7%
100,0%
60,0%
0 1 0 99,9% 96,7% 82,8%
Screen % Effective Score vs Attribute4 30 23
92,3% 80,0% 61,4%
% Appraiser
% Efficiency
94,4% 83,3% 65,3%
%Score vs Attribute2 Operator #1 Operator #2 Operator #3 30 30 30 28 29 24
0,0% Operator #1
Operator #2
Operator #3
Operator #1
Operator #2
Operator #3
Notes (1) (2) (3) (4)
Operator agrees with him/herself on both trials Operator agrees on both trials with the known standard All operators agreed within and between themselves All operators agreed within & between themselves AND agreed with the known standard
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Calculations Known Population Sample # Attribute 1 1 2 1 3 1 4 1 5 2 6 2 7 1 8 1 9 2 10 1 11 1 12 1 13 1 14 1 15 2 16 1 17 1 18 1 19 2 20 1 21 1 22 1 23 1 24 1 25 2 26 1 27 1 28 1 29 2 30 1 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 % Appraiser Score
Operator #1 Try #1 Try #2 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 2 2 1 1 1 1 2 2 1 1 1 1 1 1 2 2 1 1
100,00%
Operator #2 Try #1 Try #2 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 2 1 1
100,00%
Operator #3 Try #1 Try #2 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 2 2 1 1
Y/N Agree TRUE TRUE TRUE FALSE FALSE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE FALSE FALSE TRUE TRUE TRUE TRUE TRUE TRUE FALSE TRUE FALSE TRUE TRUE TRUE TRUE TRUE TRUE
Y/N Agree TRUE TRUE TRUE FALSE FALSE FALSE TRUE TRUE TRUE TRUE TRUE TRUE TRUE FALSE FALSE TRUE TRUE TRUE TRUE TRUE TRUE FALSE TRUE FALSE TRUE TRUE TRUE TRUE TRUE TRUE
83,33%
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