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Supplier Crater

Training and

Prevention

NPA Coatings, Inc.

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Supplier Crater Training and

Prevention

NPA recognizes that our suppliers play a

key role in the quality of our products and the

satisfaction of our customers. Opencommunication, defined expectations, and

continuous improvement are the essential

tools to a successful business relationship

and a customer first mentality.

Part of these key items are the

understanding of customer quality concerns

and the ability of every supplier to help

prevent quality issues.

Customer First Mentality

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Crater Definition:

Supplier Crater Training and

Prevention

Craters are a dish

shaped deformation in a

paint surface that may

penetrate to the layer

below the paint. They are

typically 1-4mm in

diameter.

The reason for the

formation of craters is the

difference in surface

tension between liquid

paint and a contaminant.

Microscopic

Picture of Crater

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These rendered cut-away views showthree stages (from top to bottom) of the

simulation of a crater developing: The paint layer begins flat, with a

localized concentration of a contaminate(shown in red).

A crater develops, which spreadsoutwards and increases in depth.

Once the paint is dry, the film appearsthinner and the shape of the crater is

preserved in the paint.

(The thickness of the film has beenexaggerated here.)

Crater Definition:

Supplier Crater Training and

PreventionEffects of

Contaminant to

Liquid Paint

http://www.coating.udel.edu/research/crater/images/trio.gif

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Crater Impact

Customer:

Stop production ~ Cost =$10,000 / per minute

Scrapped car bodies ~$20,000 each

Additional labor and repairs

Dumping the coating systemequals waste paint disposalcost.

2009 Lexus RXTMMC

Cambridge, Ontario

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Crater Impact

NPA and Suppliers:

Additional labor and costfor replacement material

Loss of customerconfidence

Loss of business

2009 Toyota Venza

Mfg atNAMC Kentucky

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Strong Manufacturing Program

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NPA Crater Prevention Activities

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Products:

Craters can be caused contaminationof the paint by a particle (solid or liquid)of a low surface tension.

Typical contaminates that may causecraters are oils, greases, certain types ofO-rings, plastics, and rubber gaskets.

Silicones and Teflon sealantcompounds (liquid or solid) arecontaminants that have the highestpotential of causing craters.

Potential crater causing

ingredient

Crater Prevention

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Equipment:

Ensure all parts are silicone free

Parts are disassembled and cleaned

before use Ensure replacement parts such as O-rings or gland seals are silicone free

Ensure filter manufactures do notsew using silicone lubricated needles

Crater Prevention

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Operators:

Review crater training and personalcare product lists with all newemployees, visitors, and contractors

Ensure that personal care productsare not listed on the NPA BannedIngredient List

Ensure garment cleaning does notuse or contaminate clothing withsilicone

Crater Prevention

Phenyltrimethicone

Silicadimethylsilylate

Microcrystaline Wax

Paraffin Wax

Polydimethlysiloxane

Dimethicone

Dimethiconol

Cyclomethicone

Silicone

Banned Ingedient ListPersonal Care Product

NPA Coatings, Inc.

The chemicals listed below are proven to cause craters in NPA materials.Please make sure your person care products DO NOT contain these

chemicals. Should you come into contact with such materials, ensurethey are completely cleaned off your person and possessions prior to

reporting for work.

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Crater Examples

Drums - New glue used by sub-supplier to holddrum lid gaskets in place contained material thatcause craters on several NPA products.

Totes Teflon tape used on valve assembly of

totes caused crater outbreak at two NAMCs. New totes Caustic residue was left inside newtotes which caused craters when finished productwas filled into them.

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Process Change Request

Notification of Supplier manufacturingprocess changes is a key element in craterprevention. We ask all suppliers tounderstand and utilize the NPA Process

Change Request process to help avoidproblems before they impact product quality.

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THANK YOU!