1、ABN 84 006 893 232GM Holden LimitedEngineering DepartmentMATERIAL SPECIFICATIONNUMBERSHEETRELEASEREVISION:HN 16881 of 49August, 2003June, 2013NAME: BODY AND FASCIA PAINT MATERIALS PRODUCTABILITY SIMULATIONTHIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THECOMPANYS PRODUCTS THE RECIPIENT
2、 IS RESPONSIBLE TO CONFIRM THEDOCUMENT ISSUE DATE IS STILL VALID.FORM : S:EngBusProcessEngMaterialsMatlsAndAppearanceNBRspecific0AdminMgmtStandardFormsMatspec.doc1. GENERAL DESCRIPTION1.1 INTRODUCTIONThis Productability risk assessment is an assessment made by GM Holden of the risksinvolved in intro
3、duction of a paint material into the GM Holden vehicle body paintingfacility at Elizabeth. It is used to predict the materials capability to achieve Quality andProduction metrics that are repeatable and sustainable within normal production processvariation.This specification details the testing requ
4、irements of the paint supplier and thedocumentation required for each submission to GM Holden to allow productability riskassessment approval. The information supplied in the submitted documentation will beused to advise GM Holden Manufacturing of the target application parameters required toachieve
5、 optimal appearance and quality.1.2 GENERAL REQUIREMENTS1.2.1 It is required at the plant trial stage and during the colour production run that thebasecoat colour and appearance achieved will equal or better the results achieved inthe FRA, especially on vertical surfaces for both metal and plastic p
6、aints.1.2.2 The documentation required for each submission is supplied in Appendix A ExteriorPaint Full Risk Assessment (FRA) Form Body and Fascia (pages 23-37). This mustbe submitted with the FRA each time. Incomplete submissions will not be accepted.An electronic copy can be made available by the
7、GM Holden Materials Engineer.Testing to GM9620M is required for each new basecoat colour using the formsshown in GM9620M.1.2.3 The supplier is responsible for ensuring they are working with the “current” revision ofGM Holden Specifications Film Build Ladder - Body Bell process. The supplier is requi
8、red to simulate in-line repair conditions using asimulation panel representing all GM Holden paint layers (Ecoat, Primer, Basecoatand Clearcoat) that shall be sanded and solvent wiped prior to full recoat.5.8.2 Preparation5.8.2.1 Repairs are to be performed using the same paint materials as used in
9、thenon-repaired topcoat Refer to Appendix E. Note: full recoat topcoat repairsare performed up to 2 times through GM Holden topcoat booth.5.8.2.2 Sanded area is to be performed on half of the panel and shall include a 5cmbullseye (rub through to primer) and a larger circular area 10cm (rub throughto
10、 basecoat).Note: non-sanded recoat areas are not to be scuffed, only solvent wiped.5.8.2.3 Sanding and solvent wipe activities must be performed with current Plantmaterials.5.8.2.4 The panel shall then be masked so as the sanded portion shall be recoated onhalf only with basecoat/clearcoat layer via
11、 Bell/Bell application.5.8.2.5 The recoat application settings must be identical to the settings used for theinitial topcoat layer and meet the parameter limits set in Appendix C Table 2.1.5.8.2.6 The panel shall be air-flashed and baked vertically.5.8.3 Assessment5.8.3.1 The recoated area must matc
12、h the colour and appearance of the non-repairarea and meet all criteria in section 7.25.8.3.2 Sanding or wiping marks showing in the repair layer shall be deemed notacceptable.5.9 Spot Repair and End of Line Repair (EOLR) Manually applied and cured.5.9.1 The paint supplier shall evaluate the ability
13、 of the Bell/Bell Body, Fascia or Hand-spray paint; to match the colour and appearance of the Bell/Bell applied paint as ahand-spray repair simulation.5.9.2 Preparation5.9.2.1 The paint supplier must use a gun type, materials and process, which areequivalent to that used in GM Holden Production.ABN
14、84 006 893 232GM Holden LimitedEngineering DepartmentMATERIAL SPECIFICATIONNUMBERSHEETRELEASEREVISION:HN 16889 of 49August, 2003June, 2013NAME: BODY AND FASCIA PAINT MATERIALS PRODUCTABILITY SIMULATIONTHIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THECOMPANYS PRODUCTS THE RECIPIENT IS
15、RESPONSIBLE TO CONFIRM THEDOCUMENT ISSUE DATE IS STILL VALID.FORM : S:EngBusProcessEngMaterialsMatlsAndAppearanceNBRspecific0AdminMgmtStandardFormsMatspec.doc5.9.2.2 Additional paint related materials required to facilitate the repair must be fullyapproved by GM Holden Materials Engineering as part
16、of the paint layerapproval to the relevant paint performance specification. Refer to the currentissue of the GM Holden Standard Operating Sheet (SOS) for the repairprocess details, the panels are to be sprayed, air-flashed and baked vertically.5.9.2.3 Spot Repair 5.9.2.3.1 Sanded and solvent wiped a
17、reas (bullseye approx 5cm in diameter) willneed to be prepared, refer to Appendix F for a diagram of the A3 sizerepair panel.5.9.2.3.2 Sanded areas must include sanding through to primer and basecoatlayers. With reference to GM Holden Spot Repair SOS; spray the paintusing parameters which represent
18、the GM Holden application process forthis repair.5.9.2.3.3 Clearcoat, film thickness, flash off times, cure cycles, sanding and wipingmaterials must be representative of current GM Holden productionprocesses and materials.5.9.2.3.4 The Clearcoat may blend up to 4-5cm beyond the basecoat repair, butm
19、ust not cover the whole panel.5.9.2.4 EOLR 5.9.2.4.1 Sanded and solvent wiped areas (bullseye approx 5cm in diameter) willneed to be prepared, refer to Appendix F for a diagram of the A3 sizerepair panel.5.9.2.4.2 Sanded areas must include sanding through to primer and basecoatlayers. With reference
20、 to GM Holden Spot Repair SOS; spray the paintusing parameters which represent the GM Holden application process forthis repair.5.9.2.4.3 Clearcoat, film thickness, flash off times, cure cycles, sanding and wipingmaterials must be representative of current GM Holden productionprocesses and materials
21、.5.9.2.4.4 The repair Clearcoat layer must cover the whole panel.ABN 84 006 893 232GM Holden LimitedEngineering DepartmentMATERIAL SPECIFICATIONNUMBERSHEETRELEASEREVISION:HN 168810 of 49August, 2003June, 2013NAME: BODY AND FASCIA PAINT MATERIALS PRODUCTABILITY SIMULATIONTHIS DOCUMENT MUST NOT BE REP
22、RODUCED. IF USED IN RELATION TO THECOMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THEDOCUMENT ISSUE DATE IS STILL VALID.FORM : S:EngBusProcessEngMaterialsMatlsAndAppearanceNBRspecific0AdminMgmtStandardFormsMatspec.doc5.10 Paint Circulation Stability5.10.1 The supplier is required to perfo
23、rm a circulation stability test on all basecoat paintcolours as part of the production simulation. This test is aimed at detecting changesin colour and appearance that can be attributed to the basecoat formulation beingunstable and suffering time and/or circulation degradation. The supplier must per
24、formconfirmation testing to show the correlation of their test with Holdens actual paintsystem.5.10.2 Equipment5.10.2.1 The equipment required should be similar to that listed here.5.10.2.2 Any variation to equipment and process used should be undertaken only withpermission of GM Holden Materials En
25、gineering.1 off “Binks Pogo” or “Greco”SS pump 2:1 ratio pail lid mounted with air regulator1 off 20 litre pail lid1 offframe to support equipme1 off Fluid filler1 off Fluid regulator SS1 off Pressuregauge1 off Back Pressure gauge20 metres of 6.35mm (”) ID hose asrequired fittings for hose. Refer to
26、 Figure 1 below.Figure 1 Layout of circulation stability testAirsupplyPump SS 2:1 ratio20 LpalePaint outPaint in20 metre hoseRegulatorFilterABN 84 006 893 232GM Holden LimitedEngineering DepartmentMATERIAL SPECIFICATIONNUMBERSHEETRELEASEREVISION:HN 168811 of 49August, 2003June, 2013NAME: BODY AND FA
27、SCIA PAINT MATERIALS PRODUCTABILITY SIMULATIONTHIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THECOMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THEDOCUMENT ISSUE DATE IS STILL VALID.FORM : S:EngBusProcessEngMaterialsMatlsAndAppearanceNBRspecific0AdminMgmtStandardFormsMatspec.
28、doc5.10.3 Circulation Stability Test5.10.3.1 In this test the panels (100X300mm metal panels) are to be sprayed out asdescribed in Sections 3.1 and 4.4. The paint is to be placed into the 20 litrepail and the air and back pressure regulator adjusted so that the flow of paintaround the hose experienc
29、es the equivalent of approximately 500 completevolume turnovers within a two week period. The paint will be allowed tocirculate for one week and then more simulation panels will be sprayed. Thepaint will be allowed to circulate for a further week giving two weeks of paintcirculation and then more si
30、mulation panels will be sprayed.5.10.3.2 The test is designed to identify any changes that occur to the appearance ofthe simulation panels after 0, 1 and 2 weeks of circulation in the closedsystem. The paint supplier shall correlate these findings during the 20 car trialphase of new colour introduct
31、ion.5.10.4 Assessment5.10.4.1 The simulation panels should be assessed per section 7.25.10.4.2 Colour Readings After 2 weeks the colour change shall be a very goodmatch, visually (over-riding) changes to Body and Fascia tables, changesin repair processes as specified in sections “4.4.1 Eight PlantLi
32、mitation Conditions”, “4.4.2 Spits/Dirt Generation” (of section“4.PRODUCT INFORMATION”,4.4 Application Parameters”) and“6.REPAIRABILITY”- deleted section “1.6.2 In-Line Repair” (of section “1.Paint FullRisk Assessment: BODY”, “1.6 Body Topcoat ProductabilityObservations”)- added section “1.10 Eight
33、Plant Limitation Conditions” and “1.11Spits/Dirt Evaluation”ABN 84 006 893 232GM Holden LimitedEngineering DepartmentMATERIAL SPECIFICATIONNUMBERSHEETRELEASEREVISION:HN 168816 of 49August, 2003June, 2013NAME: BODY AND FASCIA PAINT MATERIALS PRODUCTABILITY SIMULATIONTHIS DOCUMENT MUST NOT BE REPRODUC
34、ED. IF USED IN RELATION TO THECOMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THEDOCUMENT ISSUE DATE IS STILL VALID.FORM : S:EngBusProcessEngMaterialsMatlsAndAppearanceNBRspecific0AdminMgmtStandardFormsMatspec.doc9. REVISIONS (continued)February 2007(continued)- “APPENDIX B - COLOUR DEVELO
35、PMENT PROCESS”- Changes to reflect the new FRA process and order of priority forFRA simulation and Repair panel development.- “APPENDIX C - BODY PLANT APPLICATION PARAMETERS”- Updated Bell film build splits and application ranges. Added EightPlant Limitation Conditions.- section “2.Plant Process Lim
36、its”- renamed “1.Film build spits” “1.Film Build splits (Bellapplication-1st and 2nd coats)- renamed section “2.1 Bell” to “2.1 Body Paint BellApplication (1st and 2nd coats)”- deleted sections “2.2 Gun Horizontal “and “2.3 Gun-Vertical”- added section “2.2 Fascia Paint Bell Application (1st and 2nd
37、coats)”- added section “3.Eight Plant Limitation Conditions”.- “APPENDIX “D - OPACITY (OVER 25 MICRONS) EVALUATIONPANELS”- Update the graphic to reflect the new requirement specified inSection 4.3 (only multi-layer repair panel now required).- Added APPENDIX E IN-LINE REPAIR” (this Appendix shows,gr
38、aphically, the required panels noted in section “6.1 In-Line Repairs”(of section “6.REPAIRABILITY”)- Added “APPENDIX F-SPOT AND EOL REPAIRS” (this Appendixshows graphically, the required panels noted in section “6.2 SpotRepair and End of Line Repair (EOLR) Manually applied and cured”(of section “6.R
39、EPAIRABILITY”)- Added “APPENDIX G SPITS/DIRT DIAGRAM” (this Appendix showsgraphically, the required panels noted in section “4.4 ApplicationParameters” (of section “4.PRODUCT INFORMATION”).ABN 84 006 893 232GM Holden LimitedEngineering DepartmentMATERIAL SPECIFICATIONNUMBERSHEETRELEASEREVISION:HN 16
40、8817 of 49August, 2003June, 2013NAME: BODY AND FASCIA PAINT MATERIALS PRODUCTABILITY SIMULATIONTHIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THECOMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THEDOCUMENT ISSUE DATE IS STILL VALID.FORM : S:EngBusProcessEngMaterialsMatlsAndApp
41、earanceNBRspecific0AdminMgmtStandardFormsMatspec.doc9. REVISIONS (continued)April 2007 - Section “4. PRODUCT INFORMATION”, “4.4 ApplicationParameters”, “4.4.1 Eight Plant Limitation Conditions”- Reference made to visual and instrumental evaluation ofbasecoat.- “APPENDIX A RESULTS SHEET”,-Section “1.
42、 Paint Full Risk Assessment: BODY”,Table “1.10 Eight Plant Limitation Conditions, Value “6”,changed from 300/35 to 220/35.-Sections “1.4.1 Basecoat Set-up” and “2.4.1 Basecoat Set-up”,changed “psi” to “kPa”.- “APPENDIX B COLOUR DEVELOPMENT PROCESS”, Step 2.- Added detail in text, paint to match conc
43、ept.June 2007 -Section “3. DETAILED REQUIREMENTS”, section “3.1 ProcessParameters”- clarified paint layers and process for both BPS and HPO-Section “4. PRODUCT INFORMATION”, section “4.3 ProductCharacteristics”- added detail about opacity requirements-Section “4. PRODUCT INFORMATION”, section “4.4 S
44、imulationApplication Parameters”- include “Simulation” in title and comment on writtenconfirmation of parameters and colour data.-Section “4. PRODUCT INFORMATION”, section “4.4 SimulationApplication Parameters” section “4.4.1 Eight Plant LimitationConditions”- changed panel size.- Included colour an
45、d appearance requirements.-Section “4. PRODUCT INFORMATION”, section “4.4 SimulationApplication Parameters”- added section “4.4.3 Body Paint Simulation”-Section “4. PRODUCT INFORMATION”, section “4.4 SimulationApplication Parameters”- added section “4.4.4 Fascia Paint Simulation”-Section “4. PRODUCT
46、 INFORMATION”, section “4.4 SimulationApplication Parameters”- added section “4.4.5 Rocker Paint Simulation”-Section “4. PRODUCT INFORMATION”, section “4.4 SimulationApplication Parameters”- added section “4.4.6 Booth stoppages Simulation”ABN 84 006 893 232GM Holden LimitedEngineering DepartmentMATE
47、RIAL SPECIFICATIONNUMBERSHEETRELEASEREVISION:HN 168818 of 49August, 2003June, 2013NAME: BODY AND FASCIA PAINT MATERIALS PRODUCTABILITY SIMULATIONTHIS DOCUMENT MUST NOT BE REPRODUCED. IF USED IN RELATION TO THECOMPANYS PRODUCTS THE RECIPIENT IS RESPONSIBLE TO CONFIRM THEDOCUMENT ISSUE DATE IS STILL V
48、ALID.FORM : S:EngBusProcessEngMaterialsMatlsAndAppearanceNBRspecific0AdminMgmtStandardFormsMatspec.doc9. REVISIONS (continued)June 2007(continued)-Section “4. PRODUCT INFORMATION”, section “4.6 ColourReadings and Requirements”- added colour reading requirements and lighting conditions forthe assessm
49、ent.-Section “6. REPAIRABILITY”, section “6.1 In-Line Repairs”, section“6.1.1 Bell Robot Full recoat repairs are conducted through thetopcoat booth.”- added requirement to rub through to primer and basecoat for5cm and 10cm bullseye respectively.-Section “6. REPAIRABILITY”, section “6.2 Spot Repair and End ofLine Repair (EOLR) Manually applied and cured.”- added requirement for hand spray paint colour and appearanceto match the Bell/Bell Body Simulation Panel.-Section “6. REPAIRABILITY”, sectio
