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TCA and Contributions Made to Improve SMC Paintability. Mike Siwajek ThyssenKrupp Budd Company Society of Plastics Engineers Automotive Composites Conference September 9-10, 2003 Troy, MI. Goals and Objectives. Defect Root Cause Analysis. 500+ defects from 10 assembly plants catalogued - PowerPoint PPT Presentation
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TCA and Contributions Made to Improve SMC
PaintabilityMike Siwajek
ThyssenKrupp Budd Company
Society of Plastics EngineersAutomotive Composites Conference
September 9-10, 2003Troy, MI
Goals and Objectives
Defect Root Cause Analysis
• 500+ defects from 10 assembly plants catalogued
• Large percentage of defects due to microcracks from handling
• Majority of “handling” defects occurred after primer application
Root Cause Breakdown
Cracks & damage
Toughening the Matrix
• Targeting edge defects• Evaluate all components
– resins– fillers– LPA’s– additives– catalysts / inhibitors– glass
Improved Toughness
0
1000
2000
3000
4000
5000
6000
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
Strain, in/in
Str
ess
, p
si
TCA
Control
Paint Pop Flex Test• 2 x 18 x 0.1 test strips• 8.25 diameter cylindrical
mandrel• designed for 125% of ultimate
stress• deformation creates micro-
cracks on SMC surface • Paint with conventional Primer-
sealers using E-coat bake simulation (380F for 30 min.)
• count “paint pops” on surface of SMC
PP Flex Test Panels
Control Tough Class ‘A’
Verifying TCA’s Effectiveness• Multiple DOEs performed
– Ford Paint on Plastics Team / 6-sigma black belts– AOC– Red Spot
• Studied effects of– SMC type– Humidity– E-coat– Stress after molding (molding plant damage) – Stress after priming (body shop handling damage)– Type of primer (standard 2K and UV Thermal)
TCA DOE Results
• TCA less affected than control– humidity– temperature– handling
extremes
• 90+% improvement in pop resistance over control 0
20
40
60
80
100
120
140
Pops
per
pane
l
971 TCA
Desi
red
Sample Paint Pop Test Results
TCA Implementation
• TCA has afforded:– Conversion from double layer of
primer to single layer of primer without degradation in quality
– Up to 98% reduction in paint defects
– Currently less than 10 defects submitted for microscope analysis (since May 2002) - Zero Microcracks
Ford Sport Trac• Process DOE completed
in May 2002 (defect rate reduced to ~60)
• Full conversion to TCA in June 2002
• Defect rate has dropped from ~60 to below 10
0
5
10
15
20
25
30
MONTHLY 20.4 10.4 6.3 7.2 8.2 8.5 6.1 11.1 0.9 1.5 6.0 2.7
May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03
Ford T-Bird• Defect rate includes all parts
– fender converted July 2002
– decklid 07/29/02– hood 09/2002
• Level defect rate for TCA 1X primed vs standard SMC 2X
0
20
40
60
80
100
120
140
160
MONTHLY 140.6 98.7 104.5 97.6 58.1 41.8 36.7 27.8 29.9 10.9 9.5 3.0
May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03
Ford Ranger Hood
• Full conversion to TCA 08/13/02
• Defect rate dropped from ~200 to nearly 0
• Pop rate data collection suspended by assembly plant
209
222
89
11
1.1
0
50
100
150
200
250
Jun Jul Aug Sep Oct 11/1 11/4 11/5 11/6 11/7 11/8 11/11 11/12 11/13 11/14 11/15 11/18 11/19 11/20
Conversion to TCA
Lincoln Navigator Hood• Converted hood to
TCA on 06/17/02• Level defect rate
for TCA 1X primed vs. standard SMC 2X
0
20
40
60
80
100
120
140
MONTHLY 122 103 72 83 98 58 35 33 39 32 22 26 17 12 8
Feb '02 Mar '02 Apr '02 May '02 Jun '02 Jul '02 Aug '02 Sept '02 Oct '02 Nov '02 Dec '02 Jan '03 Feb '03 Mar '03 Apr '03
Lincoln Navigator Fenders
• Converted fenders to TCA August / September ‘02
• Level defect rate for TCA 1X primed vs. standard SMC 2X
0
50
100
150
200
250
300
350
400
450
500
MONTHLY 454 244 292 172 125 103 62 23 27 25 18 27 23 46 14
Feb '02 Mar '02 Apr '02 May '02 Jun '02 Jul '02 Aug '02 Sept '02 Oct '02 Nov '02 Dec '02 Jan '03 Feb '03 Mar '03 Apr '03
Ford Mustang Hood• Terminator, GT Hoods and
Decklid converted to TCA• Defect rate reduced to 0-
20• Mach 1 launched with TCA
0
10
20
30
40
50
60
70
80
90
100
MONTHLY 50 32 14 13 9 6 18 11 0 0 0 0 0 0
Oct. 02 Base
Oct. 02 GT
Nov. 02 Base
Nov. 02 GT
Dec. 02 Base
Dec. 02 GT
Jan. 03 Base
Jan. 03 GT
Feb. 03 Base
Feb. 03 GT
Mar. 03 Base
Mar. 03 GT
April 03 Base
April 03 GT
Paint pop Data Collection Suspended
by Assembly Plant
Ford Mustang Decklid
0
5
10
15
20
25
30
MONTHLY 20.4 11.8 12.8 19.9 11.8 9.9 7.8 5.3 2.9 1.3
May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03
Paint pop Data collection suspendedby assembly plant
Ford Econoline Hood
• Converted to TCA February 2003
0
20
40
60
80
100
120
140
MONTHLY 57 122 47 38 23 71 49 53 65 120 93 105 19 6 4
Feb '02 Mar '02 Apr '02 May '02 Jun '02 Jul '02 Aug '02Sept '02
Oct '02 Nov '02 Dec '02 Jan '03 Feb '03 Mar '03 Apr '03
Conversion to TCA
What next???• Remove the Class ‘A’ SMC Stigma at
OEMs– Tough Class ‘A’– UV Thermal Primer– New primer-sealer technologies
• SMC Consistency Program– Best practices (compounding and
molding)– Defect traceability– Eliminate variability
SMC Consistency Improvement Plan
• Target programs for improvement• Identify Key Performance Criteria (KPCs)
– as defined by customer (molding plant or OEM)
• Target broad cross-section of causes for inconsistencies (Control Factors / CFs)
• Form cross-functional teams to focus on this effort
• Stepwise regression of defects vs. CFs• Develop a sound engineering basis for the
effort
SMC Consistency Roadmap
yesno
Data Gathering
Implement in production
Establish CF statistical capability
Data Gathering to verify improvement
Conduct experiments to verify failure mode
Data Analysis - identify possible CF's
Brainstorm - understand failure mode
failure mode
identified ?
Acknowledgements
• SPE
• Ford GPE
• AOC
• Red Spot
• TK-Budd Team
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