VDA Volume 16 Englisch Pictures

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 2 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd 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 bydendritic separation in the limit current area (referredto 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)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 4 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No. 8: Colour differences

    Data:

    Definition: Colour deviation on a surface by comparison with theneighbouring surface or reference sample. This resultsfrom :

    (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 ofcomponents, such as are caused by surface tensions.

    The effect correlates primarily with the edge radiusand/or the position of the component during theprocess.

    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, causedfor 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 residueson 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

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 5 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd 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 overcomplete 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 earlierprocess (e.g., stamping burrs on cut edges; flash onplastic 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 diffusereflection 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)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 6 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No. 16: Contact / gripping points

    Data:

    Definition: Small areas, usually as spots where paint / c oating ismissing (in an area not normally visible), caused bysuspension 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 inappropriatehandling.(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 < 0,5mmMax. 2 scratches within 300 mm

    Zone B: L < 10mm, W < 0,7mmMax. 4 scratches within 200 mm

    Examples of permissible characteristic features ( ransverse):

    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, onvertical 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 notfelt: paint runs / streaks i n 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)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 7 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No. 20: Thin coating areas

    Data:

    Definition: Inadequate top coating (the substrate can be seenthrough 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 deformationor 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-holesover 4 cm

    2permitted

    Zone B: Pin-holes permitted

    No. 23: Nickel patches

    Data:

    Definition: Yellowish places in the contact area and in areaswhere 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)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 8 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No illustration available

    No. 24: "Orange-peel" effect

    Data:

    Definition: A rough or wave-like appearance of a painted surfacewhich may contain a texture; a grained paint finish withthe 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 forseverity and surface area.

    Zone B: A coarse structure is permitted refer to limit samplefor 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 whichthe part was formed. The degree of visibility dependson the type and quantity of oxide inclusions.

    Process allocation: 11

    Examples of permissible characteristic features:

    Zone A: Not permitted if s ructures visible at a distance of > 800 mm.

    Zone B: Not permitted if s ructures 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 orgrowths 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)

    Zone B: Refer to MTP sample(s)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 9 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No illustration available

    No illustration available

    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 bymaterial residues which have been polished in.

    Dull areas: These occur following electrolytic sheening andare caused by excessive local heating; alsosurfaces areas which have not been sufficientlypolished.

    Holograms: Polishing defects with a 3-dimensional effect.These occur particularly with dark paint colours.

    Polishing flecks: Restricted circular areas with a muchsmoother 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 materialresidues which have been polished in.

    Process allocation:

    Examples of permissible characteristic features:

    Zone A: Refer to MTP sample(s)

    Zone B: Refer to MTP sample(s)

    No. 28b: Dull areas

    Data:

    Definition: These occur following electrolytic sheening and arecaused by excessive local heating; also surfaces areaswhich 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. Theseoccur particularly with dark paint colours.

    Process allocation:

    Examples of permissible characteristic features:

    Zone A: Refer to MTP sample(s)

    Zone B: Refer to MTP sample(s)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 10 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No. 28d: Polishing flecks

    Data:

    Definition: Restricted circular areas with a much smoothersurface 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 s hape similar to that of a fish, causedduring the polishing process by a foreign body, a poreor other pre-conditioning from earlier processes, suchas grinding.

    Process allocation: 6, 9, 11, 13

    Examples of permissible characteristic features:

    Zone A: D < 0.3 mm, W < 2.5 mm, L < 5 mmMax. 2 within a spacing of 400 mm

    Zone B: D < 0.5 mm, W < 3 mm, L < 8 mmMax. 4 within a spacing of 300 mm

    No. 30: Polishing streaks

    Data:

    Definition: Very fine, localised raising of visible ribs, caused bythe 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 topcoating, which may penetrate to the base material inplaces.

    Process allocation: 2, 3, 6, 13, 15

    Examples of permissible characteristic features:

    Zone A: See Section 10.2

    Zone B: See Section 10.2

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 11 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No illustration available

    No illustration available

    No. 32: Indications of seams / seam-welds

    Data:

    Definition: Identification:Traces of longitudinal seams (extrusion press marks)Traces of weld areas.

    Descrip ion & effects:

    Traces of (narrow) streaks, running in the direction in whichhe part was formed, where the area is seen as lighter ordarker than the surrounding material, depending on lightingconditions. They can also occur in association with sink-marksor step-marks. Indications of longitudinal seam / seam-weldsare caused by manufacturing processes and are unavoidable;however, the level of their appearance can be influenced.

    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 asdifferences 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 thepressing / extrusion, over the length of the profile,generally in the form of steps , which are especiallyvisible after a coating process.

    Process allocation: 4, 6, 8, 15

    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 resultingfrom 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)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 12 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No. 36: Graininess

    Data:

    Definition: Slight graininess of a galvanised surface; comparablewith 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: ave-like, parallel marks on the surface of the panel or profile,at an angle to the direction of rolling or compression, whichcan be seen in special observation positions (e.g., looking inhe 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 mwhen evaluated as described for Zone A

    No. 38a: Cloudiness/ fogging/ streaks

    Data:

    Definition: hen polishing: local areas which are matt, dull, cloudy orstreaky, with diffuse transfer between different areas (processallocation 9).

    hen painting: noticeable, partially light or dark areas within a(metallic) paint finish with diffuse transfer from one area to thenext (process allocation 3).Dull areas within the overall surface; with diffuse transfer fromone area to the nextProcess 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 arecaused by moisture in the plastic or air inclusionsduring 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)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 13 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No. 39: Differences in coating thicknesses

    Data:

    Definition: These occur during galvanizing as a result ofinappropriate current density distribution (processallocation 6) or in other processes because of differentparticulate flows / flow angles or separation conditions.

    Process allocation: 2, 3, 6Examples 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 onthe other side of the component, such as ribs, stepsand domes (process allocation 6).Dents in the surface, caused by inappropriate

    component geometry and / or shrinkage (processallocation 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 whereflow 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 rubbersuckers. 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)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 14 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No illustration available

    No illustration available

    No. 43: Seam welds

    Data:

    Definition: These occur at the convergence of two mass flowsafter piercings and domes (converging seam welds).

    Process allocation: 12, 13, 15

    Examples of permissible characteristic features:

    Zone A: Refer to MTP sample(s)

    Zone B: Refer to MTP sample(s)

    No. 44: Moisture inclusions

    Data:

    Definition: Damp material, caused by incorrect preparation of thematerial. Expanding moisture is deposited as streaksor bubbles on the surface of the article.

    Process allocation: 2, 5, 12, 13

    Examples of permissible characteristic features:

    Zone A: Not acceptable

    Zone B: Refer to MTP sample(s) Acceptable

    No. 45: Holes

    Data:

    Definition: Holes in the surface coating, visible with the nakedeye, 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 isvisible.

    Alignment offset :Caused by inaccurate alignment of veneer / an offset

    in structural symmetryProcess allocation: 13

    Examples of permissible characteristic features:

    Zone A: Refer to MTP sample(s)

    Zone B: Acceptable

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 15 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd 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 / deburringthe 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 adequatelyformed. 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

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 16 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    No illustration available

    No illustration available

    No. 51: Paint residues

    Data:

    Definition: Parts of the surface have not been removed by thelaser process.

    Process allocation: 17

    Examples of permissible characteristic features:

    Zone A: Not acceptable

    Zone B: Refer to MTP sample(s)

    No. 52: Burn marks

    Data:

    Definition: Thermal changes in the plastic substrate (changes incolour).

    Process allocation: 5, 17

    Examples of permissible characteristic features:

    Zone A: Refer to MTP sample(s)

    Zone B: Refer to MTP sample(s)

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    Source Legend:

    1) Anodizing2)Powder coating (EPS)3)Wet painting4)Extrusion5) Injection moulding6)Galvanizing

    7) Plasma process (evaporation, sputter, CVD, PVD)8) Over-moulding9) Polishing10) Assembly / packaging / handling11)Incoming material12)Plastic processing

    13)Refined wood surfaces14) Application technology (gluing insert foils, embossing decorative foils)15)Metal die-casting16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)17)Laser lettering

    Page 17 of 17

    Decorative Surface ofAttachment & Functional Parts to theExterior and Interior of Automobiles16 Appendix to VDA Volume 162nd revised edition, 2008

    Imprint

    The entire contents of these pages are protected by copyright.

    Responsible for contents:

    VDA QMCQualitts Management Centerim Verband der AutomobilindustrieVDA QMCAn den Drei Hasen 31D-61440 OberurselGERMANY

    Phone: +49 (0)6171 / 9122-0Fax: +49 (0)6171 / 9122-14E-Mail: [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

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    Attribute Gage R & R Effectiveness

    Instructions:

    1) 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.2) In theData Entryworksheet 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.

    3) If you or an expert has selected samples to be evaluated and you know what attributes these

    samples are, enter this information in the Attributesample 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.

    4) 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.

    5) To print a copy of the report click on thePrint Reporticon.

    6) To delete the data in the spreadsheet, click on theDelete Dataicon.

    7) To delete all and begin a new test, click on theDelete Allicon

    8) To see a Demo of the Attribute GR&R Effectiveness spreadsheet, click on theDemoicon.

    Move around the spread sheet to see the data. When you are finished click theDelete 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 30 < Try out different combinations of number of samples and number of matches

    # Matches 30 < to see the effects of sample size. In this case, a sample size of 30 with

    95% UCL 100,0% < one non-match will yield a 17% confidence interval. In order to get reasonable

    Calculated Score 100,0% < reliability in estimates of efficiency, large sample sizes will be required.

    95% LCL 88,4%

    Page 1 of 5Attributiven_Gage_R&R-Studie

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    Data Entry

    Attribute Gage R & R Effectiveness

    SCORING REPORT

    DATE: 04.01.2001

    Attribute Legend

    5

    (used in computations) NAME: Acme Employee1 Pass PRODUCT: Widgets All operators

    2 Fail BUSINESS: Earth Products agree within and All Operatorsbetween each agree with

    Other standard

    Known Population Y/N /N

    Sample # Attribute Try #1 Try #2 Try #1 Try #2 Try #1 Try #2 Agree Agree

    1 Pass Pass Pass Pass Pass Pass Pass Y Y

    2 Pass Pass Pass Pass Pass Pass Pass Y Y

    3 Pass Pass Pass Pass Pass Pass Pass Y Y

    4 Pass Pass Pass Pass Pass Fail Pass N N

    5 Fail Fail Fail Fail Fail Pass Fail N N

    6 Fail Pass Pass Pass Pass Pass Pass Y N

    7 Pass Pass Pass Pass Pass Pass Pass Y Y

    8 Pass Pass Pass Pass Pass Pass Pass Y Y

    9 Fail Fail Fail Fail Fail Fail Fail Y Y

    10 Pass Pass Pass Pass Pass Pass Pass Y Y

    11 Pass Pass Pass Pass Pass Pass Pass Y Y

    12 Pass Pass Pass Pass Pass Pass Pass Y Y

    13 Pass Pass Pass Pass Pass Pass Pass Y Y

    14 Pass Pass Pass Pass Pass Fail Pass N N

    15 Fail Fail Fail Fail Fail Pass Fail N N

    16 Pass Pass Pass Pass Pass Pass Pass Y Y

    17 Pass Pass Pass Pass Pass Pass Pass Y Y

    18 Pass Pass Pass Pass Pass Pass Pass Y Y

    19 Fail Fail Fail Fail Fail Fail Fail Y Y

    20 Pass Pass Pass Pass Pass Pass Pass Y Y

    21 Pass Pass Pass Pass Pass Pass Pass Y Y

    22 Pass Fail Fail Pass Pass Pass Pass N N

    23 Pass Pass Pass Pass Pass Pass Pass Y Y24 Pass Pass Pass Pass Pass Fail Pass N N

    25 Fail Fail Fail Fail Fail Fail Fail Y Y

    26 Pass Pass Pass Pass Pass Pass Pass Y Y

    27 Pass Pass Pass Pass Pass Pass Pass Y Y

    28 Pass Pass Pass Pass Pass Pass Pass Y Y

    29 Fail Fail Fail Fail Fail Fail Fail Y Y

    30 Pass Pass Pass Pass Pass Pass Pass Y Y

    31

    99

    100

    % APPRAISER SCORE(1)

    -> 100,00% 100,00% 83,33%

    SCORE VS. ATTRIBUTE(2)

    -> 93,33% 96,67% 80,00%

    SCREEN % EFFECTIVE SCORE(3)

    -> 80,00%SCREEN % EFFECTIVE SCORE vs. ATTRIBUTE

    (4)-> 76,67%

    Note:(1)Operator agrees with him/herself on both trials

    (2)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

    Operator #1 Operator #2 Operator #3

    Page 2 of 5Attributiven_Gage_R&R-Studie

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    ReportAttribute Gage R & R Effectiveness

    SCORING REPORT

    DATE: 04.01.2001

    Attribute Legend NAME: Acme Employee

    1Pass PRODUCT: Widgets All operators

    2Fail BUSINESS: Earth Products agree within and All Operatorsbetween each agree with

    O th er s ta nd ar d

    Known Population Operator #1 Operator #2 Operator #3 Y/N Y/N

    Sample # Attribute Try #1 Try #2 Try #1 Try #2 Try #1 Try #2 Agree Agree

    1 Pass Pass Pass Pass Pass Pass Pass Y Y

    2 Pass Pass Pass Pass Pass Pass Pass Y Y

    3 Pass Pass Pass Pass Pass Pass Pass Y Y

    4 Pass Pass Pass Pass Pass Fail Pass N N5 F ail Fail Fail Fail Fail Pass Fail N N6 Fail Pass Pass Pass Pass Pass Pass Y N

    7 Pass Pass Pass Pass Pass Pass Pass Y Y

    8 Pass Pass Pass Pass Pass Pass Pass Y Y9 Fail Fail Fail Fail Fail Fail Fail Y Y

    10 Pass Pass Pass Pass Pass Pass Pass Y Y

    11 Pass Pass Pass Pass Pass Pass Pass Y Y12 Pass Pass Pass Pass Pass Pass Pass Y Y

    13 Pass Pass Pass Pass Pass Pass Pass Y Y

    14 Pass Pass Pass Pass Pass Fail Pass N N15 Fail Fail Fail Fail Fail Pass Fail N N

    16 Pass Pass Pass Pass Pass Pass Pass Y Y

    17 Pass Pass Pass Pass Pass Pass Pass Y Y18 Pass Pass Pass Pass Pass Pass Pass Y Y

    19 Fail Fail Fail Fail Fail Fail Fail Y Y

    20 Pass Pass Pass Pass Pass Pass Pass Y Y21 Pass Pass Pass Pass Pass Pass Pass Y Y

    22 Pass Fail Fail Pass Pass Pass Pass N N

    23 Pass Pass Pass Pass Pass Pass Pass Y Y24 Pass Pass Pass Pass Pass Fail Pass N N

    25 Fail Fail Fail Fail Fail Fail Fail Y Y

    26 Pass Pass Pass Pass Pass Pass Pass Y Y27 Pass Pass Pass Pass Pass Pass Pass Y Y

    28 Pass Pass Pass Pass Pass Pass Pass Y Y

    29 Fail Fail Fail Fail Fail Fail Fail Y Y

    30 Pass Pass Pass Pass Pass Pass Pass Y Y31 - - - - - - -

    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(1)

    -> 100,00% 100,00% 83,33%

    % SCORE VS. ATTRIBUTE(2)

    -> 93,33% 96,67% 80,00%

    SCREEN % EFFECTIVE SCORE(3)

    -> 8 0, 00 %

    SCREEN %EFFECTIVE SCORE vs. ATTRIBUTE(4)

    -> 76,67%

    Note:(1)Operator agrees with him/herself on both trials(2)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 Page 3 of 5

    Attributiven_Gage_R&R-Studie

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    Statistical Report - Attribute Gage R&R Study

    DATE: 04.01.2001NAME: Acme Employee

    PRODUCT: WidgetsBUSINESS: Earth Products

    % Appraiser1

    %Score vs Attribute2

    Source Operator #1 Operator #2 Operator #3 Operator #1 Operator #2 Operator #3

    Total Inspected 30 30 30 30 30 30

    # Matched 30 30 25 28 29 24

    False Negative (operator rejected good product) 1 0 0

    False Positive (operator accepted bad product) 1 1 1

    Mixed 0 0 5

    95% UCL 100,0% 100,0% 94,4% 99,2% 99,9% 92,3%

    Calculated Score 100,0 100,0% 83,3% 93,3 96,7 80,0%

    95% LCL 88,4% 88,4% 65,3% 77,9% 82,8% 61,4%

    Screen % Effective Score3

    Screen % Effective Score vs Attribute4

    Total Inspected 30 30

    # in Agreement 24 23

    95% UCL 92,3% 90,1%

    Calculated Score 80,0% 76,7

    95% LCL 61,4% 57,7%

    Notes

    (1) Operator agrees with him/herself on both trials

    (2) Operator agrees on both trials with the known standard

    (3) All operators agreed within and between themselves

    (4) All operators agreed within & between themselves AND agreed with the known standard

    % Appraiser

    0,0%

    10,0%20,0%

    30,0%

    40,0%

    50,0%

    60,0%

    70,0%

    80,0%

    90,0%

    100,0%

    110,0%

    Operator #1 Operator #2 Operator #3

    %

    Efficiency

    95% UCLCalculated Score95% LCL

    % Score vs Appraiser

    0,0%

    10,0%20,0%

    30,0%

    40,0%

    50,0%

    60,0%

    70,0%

    80,0%

    90,0%

    100,0%

    110,0%

    Operator #1 Operator #2 Operator #3

    %

    Efficiency

    95% UCLCalculated Score95% LCL

    Page 4 of 5Attributiven_Gage_R&R-Studie

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    CalculationsKnown Population Operator #1 Operator #2 Operator #3 Y/N Y/N

    Sample # Attribute Try #1 Try #2 Try #1 Try #2 Try #1 Try #2 Agree Agree

    1 1 1 1 1 1 1 1 TRUE TRUE

    2 1 1 1 1 1 1 1 TRUE TRUE

    3 1 1 1 1 1 1 1 TRUE TRUE

    4 1 1 1 1 1 2 1 FALSE FALSE

    5 2 2 2 2 2 1 2 FALSE FALSE

    6 2 1 1 1 1 1 1 TRUE FALSE

    7 1 1 1 1 1 1 1 TRUE TRUE

    8 1 1 1 1 1 1 1 TRUE TRUE

    9 2 2 2 2 2 2 2 TRUE TRUE

    10 1 1 1 1 1 1 1 TRUE TRUE

    11 1 1 1 1 1 1 1 TRUE TRUE

    12 1 1 1 1 1 1 1 TRUE TRUE

    13 1 1 1 1 1 1 1 TRUE TRUE

    14 1 1 1 1 1 2 1 FALSE FALSE

    15 2 2 2 2 2 1 2 FALSE FALSE

    16 1 1 1 1 1 1 1 TRUE TRUE

    17 1 1 1 1 1 1 1 TRUE TRUE

    18 1 1 1 1 1 1 1 TRUE TRUE

    19 2 2 2 2 2 2 2 TRUE TRUE

    20 1 1 1 1 1 1 1 TRUE TRUE

    21 1 1 1 1 1 1 1 TRUE TRUE

    22 1 2 2 1 1 1 1 FALSE FALSE

    23 1 1 1 1 1 1 1 TRUE TRUE

    24 1 1 1 1 1 2 1 FALSE FALSE

    25 2 2 2 2 2 2 2 TRUE TRUE

    26 1 1 1 1 1 1 1 TRUE TRUE

    27 1 1 1 1 1 1 1 TRUE TRUE

    28 1 1 1 1 1 1 1 TRUE TRUE

    29 2 2 2 2 2 2 2 TRUE TRUE

    30 1 1 1 1 1 1 1 TRUE TRUE

    31

    32

    3334

    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

    7475

    76

    77

    78

    79

    80

    81

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    83

    84

    85

    86

    87

    88

    89

    90

    91

    92

    93

    94

    9596

    97

    98

    99

    100

    %Appraiser Score 100 00 100 00% 83 33 Page 5 of 5