Scribd
Upload
80 views

Contamination Control Best Practices Overview

The document discusses contamination control best practices for a paint shop. It identifies four main focus areas: people, process, material, and facilities. For people, it recommends approved low-lint attire, gloves, and hair protection. For process, it discusses utilizing contamination control manuals and best practices. For material, it recommends only approved direct/indirect materials. For facilities, it recommends utilizing bills of process and facility specifications. The document provides details on each focus area and specific recommendations to minimize contamination sources.

Uploaded by

Hiren Parmar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
80 views

Contamination Control Best Practices Overview

The document discusses contamination control best practices for a paint shop. It identifies four main focus areas: people, process, material, and facilities. For people, it recommends approved low-lint attire, gloves, and hair protection. For process, it discusses utilizing contamination control manuals and best practices. For material, it recommends only approved direct/indirect materials. For facilities, it recommends utilizing bills of process and facility specifications. The document provides details on each focus area and specific recommendations to minimize contamination sources.

Uploaded by

Hiren Parmar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 19

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
Facilities Key Issues Continued
• 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
Facilities Key Issues Continued
• 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

You might also like