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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.gif7/30/2019 A Supplier Crater Training
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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!