Contamination Control Best Practices Overview

Paint Shop
Contamination Control
Best Practices
1
What Methods Are Available To Control The Sources?
Sources of Contamination Data
• Data before controls were established

– Studies of paint contamination defects at many
GM, Ford, and Chrysler plants by BASF in late
1980s
• Data after controls were established
– Contamination Control Manual - Appendix B
– Fibers (Primarily from people) - 42 to 50% After
controls were implemented - About 4%
Paint Shop Contamination Control
Four Main Focus Control Areas
• People Utilize principles from “Contamination Control

Manual”
• Process Utilize principles from “Contamination Control
Manual” and appropriate process “Best
Practices”
• Material Utilize only approved direct/indirect materials
• Facilities Utilize “Bill of Process” and “Facilities
Technical Specifications”
Paint Shop Attire Lint Generation Equivalents
Street Clothes
= 50-150
LowLint
Low LintShop
Shop
Coat==25-40
Coat 25-40
OpenNeck
Open Neck
Coverall==66
Coverall
Corporate
Corporate
Coverall==11
Coverall
0 10 20 30 40 50 60 70 80 90 100
Relative Unit Amounts Generated per Person
Lint can remain in the air stream for hours without air turbulence and indefinitely with
minor air turbulence. Do not introduce lint into a paint shop
Fabric Lint Potential
COTTON BASED
LOW LINT MATERIALS MATERIALS
TAPE TEST-LINT/M2
200 PARTICLE COUNT AREA
VACUUM TEST
TUMBLE TEST
150
RELATIVE
TEST VALUE
NUMBER
100 STATICALLY GROUNDED
(Except Combinoto)
Old coverall with

poor repair
50
0
CHEMSTAT GUILFORD BURLINGTON CHEMSTAT COMBINOTO COTTON 100%
949 MILLS MILLS 909 (Unkown BLEND COTTON
31216 C3 Material)
Fiber Data on SLP Startup
75% Of The Paint Defects Are Fibers
Possibly generated during construction

from street clothes. Almost everyone
dressed in blue jeans and white cotton
shirts
Key Issues in the People Area
• Approved attire including hair protection on all

Paint Shop employees
– Protect the vehicle from contamination
• Approved low fiber gloves on everyone in
contact with vehicle
Would you want this guy to work around the

vehicle without coveralls , gloves and hair
cover?
Comparative Fabric Lint Generation
• Lab testing of different materials
– Approved coverall versus “street clothes”
– Approved wiper versus terry cloth towel

Garment Comparison
930 Particles/m2 395,000 Particles/m2
500 µm 500 µm
Figure 1. Clean Coverall Figure 2. “Street Clothes”

> 400 times more fibers
Wiper Comparison
930 Particles/m2 395,000 Particles/m2

500 µm 500 µm
Figure 1. Approved Cleanroom Wiper Figure 2. Terry Cloth Towel

> 400 times more fibers
People Key Issues Continued
• No fibrous material in Paint Shop Floor

(newspapers, paper towels, cardboard, etc.)
• Strive to eliminate all lint containing materials
• Food/Smoking only in enclosed break /
cafeteria areas
• “Contamination Awareness” training for all
Paint Shop employees
People Key Issues Continued
• Functional Contamination Control Team in place

• Only approved indirect materials utilized
• All employees responsible for the personal
housekeeping of their Area
• Create people and vehicle traffic patterns that
minimize the potential to contaminate vehicle
• Entire Paint Shop should be considered a
“Clean Area” to reduce contamination sources
Key Issues in the Process Area
• Total Process Operation based on Paint Shop
Common Process Control Plan
• Utilize Synchronous/5S workplace organization
• Filter change process, booth/oven cleaning
schedule, etc. based on statistical data
• Preventative maintenance, cleaning and
balancing of paint circulating systems
• Utilize only approved indirect materials
Process Key Issues Continued
• Use defect prevention to minimize sanding and use
only spot moist defect sanding
• Self-inspection/Clean-up on Seal Line
• Incoming material control for contamination sources
• Develop continuous cleaning process for tools,
fixtures, carriers and skids
• Immaculate housekeeping and continuous facility
and equipment cleaning/repainting
• All facility/equipment installations must include a
deep clean process
Key Issues in the Facilities Area
• All facilities/equipment based on Paint
Engineering BOP and technical specifications
• Low contaminant-generating conveyor systems
(i.e. pendulum, skids)
• Floor conveyors begin at E-Coat oven
• Locate all paint booths in a minimum-sized
cleanroom, minimize cleanroom access with air
shower entries only
• Control entry into clean areas of paint shop with
air showers
Facilities Key Issues Continued
• Paint booth quality air supplies for cleanroom
• Clean-wall designs for bells and robot rails
• Temperature and humidity control in Paint Mix
Room (ambient air temperature must be below
paint temperature)
• Sanding and Finesse/Polish in enclosed booths
with wet pan floors and negative air balance
• All booth enclosure penetrations must be sealed
• Bottom-entry, indirect-fired ovens
• Protect vehicle with a clean tunnel or canopy in all
critical areas
• All paint carriers confined to Paint Shop
• All floors and exposed concrete sealed
• Dryers, coalescing filters and oil vapor elimination
for compressed air supply to Paint shop
• Blow-downs for compressed air headers with drip
legs at all drops
• Motor and agitator compressed air exhaust into
contained headers
• Maintain 50% RH minimum levels in all Paint
Shop environments
• Maintain a positive air flow sequence (i.e.
Booths > Clean Room > Paint Shop > Outside)
• Area cooling, if required, for work areas (no man
fans)
• Enclosed/Air-conditioned break areas
• Wash basins and hot air dryers (no paper
towels) in break areas

Contamination Control Best Practices Overview

Uploaded by

Copyright:

Available Formats

Contamination Control Best Practices Overview

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Contamination Control Best Practices Overview

Uploaded by

Copyright:

Available Formats

Paint Shop

• Data before controls were established

• People Utilize principles from “Contamination Control

Old coverall with

75% Of The Paint Defects Are Fibers

Possibly generated during construction

• Approved attire including hair protection on all

Would you want this guy to work around the

• Lab testing of different materials

– Approved coverall versus “street clothes”

– Approved wiper versus terry cloth towel

Figure 1. Clean Coverall Figure 2. “Street Clothes”

930 Particles/m2 395,000 Particles/m2

Figure 1. Approved Cleanroom Wiper Figure 2. Terry Cloth Towel

• No fibrous material in Paint Shop Floor

• Functional Contamination Control Team in place

You might also like