SUPPLIER CONTAMINATION PREVENTION Guidelines and Awareness Training SUPPLIER
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SUPPLIER CONTAMINATION PREVENTION Guidelines and Awareness Training
SUPPLIER CONTAMINATION PREVENTION Agenda • • Purpose Contamination and Craters Recommendations Summary
SUPPLIER CONTAMINATION PREVENTION Purpose • Contamination continues to be an issue at PPG • Multiple occurrences related to raw materials, containers or transport • Awareness training is part of PPG’s overall contamination prevention strategy
SUPPLIER CONTAMINATION PREVENTION What do we mean by contamination?
SUPPLIER CONTAMINATION PREVENTION What do we mean by DIRT? • Any particulate or fibres found in our paint – excessive dirt can cause sanding issues at our customer site.
SUPPLIER CONTAMINATION PREVENTION What is a CRATER? Craters are dish shape deformations in a paint surface. Some are shallow dimples, others are deep that penetrate to the substrate or layer below
SUPPLIER CONTAMINATION PREVENTION Cost of Craters Disruption of an OEM assembly line Approximately $10, 000 per minute!
SUPPLIER CONTAMINATION PREVENTION Cost of Contamination • Additional labor for sanding, repairs and rework • Car bodies scrapped - $3000 each • Paint system at OEM dumped & cleaned - $4000 + disposal costs • Scrapped inventory at PPG • Laboratory testing, site investigations and supplier claims
SUPPLIER CONTAMINATION PREVENTION BIGGEST Cost of Contamination Loss of Customer Confidence Loss of business to PPG
SUPPLIER CONTAMINATION PREVENTION Solvent Tank Wagons - Sampling and Testing • Sampling attachment used on incoming solvent tank wagons • Filter allows PPG to assess amount of particles and fibers • Gels can be an indicator of crater causing contamination • Failed testing will result in a rejected tank wagon
SUPPLIER CONTAMINATION PREVENTION Tank Wagons – Sampling and Testing • 500 wagons are tested annually at PPG Cleveland • 7 wagons have been rejected in 2012 because of excessive contamination • Other PPG locations experiencing tank wagon issues as well • Audits and corrective actions implemented at suppliers
SUPPLIER CONTAMINATION PREVENTION Tank Wagons - Requirements Prior Contents • Use dedicated tank wagons where possible • If not dedicated, must have a system of reviewing prior contents of each tank wagon used for PPG Material • Use PPG list of prohibited materials in review of prior contents - contact PPG if there are ANY questions!
SUPPLIER CONTAMINATION PREVENTION Tank Wagons - PPG Requirements Prior Contents Prohibited List • • • Silicones Fluorocarbons and fluorine based additives Pigment dispersing agents Release agents and adhesion promoters Refrigerants Waxes and cleaning compounds Greases and oils Epoxy resin, cationic epoxy and aqueous epoxy Acrylic emulsions Strong acids and bases Slurries, dry powder and dispersions
SUPPLIER CONTAMINATION PREVENTION Tank Wagons - PPG Requirements Cleaning Methods • Ensure correct cleaning methods − Caustic clean (no detergent) + thorough rinsing − External bottom valve and dome lid disassembled and − cleaned Inside inspection – visual and feel • Procedure for pre-cleaning a new tank wagon must be in place − preliminary testing required before filling
SUPPLIER CONTAMINATION PREVENTION Containers – Approval and Testing Totes, Drums, Pails • All containers types must be pre-approved by PPG • Tote cleaners are audited annually • Drum and pail manufacturers are also audited • Drums are sampled from every new lot received and tested for dirt
SUPPLIER CONTAMINATION PREVENTION Maintenance Materials Controls Maintenance List + Visual Aids PPG’s controlled list is called MRL (Material Registration List) • All maintenance materials at PPG are crater tested • Maintenance materials that FAIL are eliminated where possible • A system has been created with stickers that is understood by all employees
SUPPLIER CONTAMINATION PREVENTION Maintenance Materials Controls Use of stickers as a visual aid
SUPPLIER CONTAMINATION PREVENTION Products that scare us! • • WD-40 widely used but causes craters Rain X widely used but causes craters Silicone based lubricants Greases with low surface tension components • There are equivalent products available to use in place of failed products SEE PPG’s LIST!
SUPPLIER CONTAMINATION PREVENTION Processing Equipment Pre-Cleaning ‘de-bugging’ • Any equipment that is new must be pre-cleaned – disassembled and cleaned with solvent, then tested • Pre-cleaning should be done after all repairs or replacements
SUPPLIER CONTAMINATION PREVENTION Processing Equipment - Purchasing Valves, gaskets, etc. • Establish a silicone free purchasing policy for valves • Maintain a list of approved equipment that can be purchased • Equipment still needs precleaning Drum valve failed testing!
SUPPLIER CONTAMINATION PREVENTION Gaskets Used in Hoses/Totes • Gaskets sampled and tested - failed • Gasket supplier used silicone release agent • Now have new gaskets • Use “Talc” for release and will • Have an orange stripe to signify “Talc release”
SUPPLIER CONTAMINATION PREVENTION Silicone Handling Visual Controls at PPG for Silicone Materials • • Pink label Pink skid Quarantine area Designated equipment for weighing and dispensing
SUPPLIER CONTAMINATION PREVENTION Silicone Handling at PPG “SILICONE ONLY” tools WASTE pails for Silicone Storage Bin for designated tools 23
SUPPLIER CONTAMINATION PREVENTION Gloves Nitrile Gloves • Gloves have caused false results in crater testing • Silicone is commonly used in the glove manufacturing process – release agent • Need to specify silicone-free gloves from distributor
SUPPLIER CONTAMINATION PREVENTION Work Wear Operators’ Clothing • PPG garments have been tested • Garment manufacturing and cleaning process has been audited and reviewed —No silicone additives in detergents —No silicone infused thread
SUPPLIER CONTAMINATION PREVENTION Personal Care Products Silicone Free! Hand Lotions • Over 50 hand lotions were tested for craters - 95% failed! • Recommendation: provide APPROVED hand lotion in production and laboratory areas
SUPPLIER CONTAMINATION PREVENTION Personal Care Products Critical in certain processes Evaluate risk at your facility!
SUPPLIER CONTAMINATION PREVENTION The Tale of Two Deodorants The Good (passes) 24 H Deodora nt Invisible Solid The Bad (fails) 24 H Anti. Perspirant & Deodorant Stick The UGLY!
ATTENTION: Jim Blagg / QA Core, Bldg 4 SUPPLIER CONTAMINATION PREVENTION Personal Hygiene • Wash hands after meals – some food ingredients cause craters • Change out heavily soiled garments, shoes or gloves • Wear gloves when directly handling materials 29
SUPPLIER CONTAMINATION PREVENTION Housekeeping and Contamination Prevention Key Areas • Raw material containers & skids
SUPPLIER CONTAMINATION PREVENTION Housekeeping and Contamination Prevention Key Areas • Processing equipment • Blending vessels • Transfer pumps • Sampling cups • Spill containment
SUPPLIER CONTAMINATION PREVENTION Overall Housekeeping • Decrease risk of contamination • Decrease risk of errors
SUPPLIER CONTAMINATION PREVENTION SUMMARY q q Contamination prevention critical for PPG Guidelines and recommended procedures § Bulk tank wagons – prior contents & cleaning § Bulk tank wagons – sampling & testing § Drums – tested, totes cleaners – audited § Maintenance materials – listed and controlled § Pre-cleaning – all new or repaired equipment § Silicone handling – procedures and quarantine § Work wear – tested and approved
SUPPLIER CONTAMINATION PREVENTION SUMMARY Personal care products § Use only approved hand lotion § Evaluate risk of personal care products § Personal hygiene – washing hands q Housekeeping is critical § Cleaning procedures and visual controls § Keeping lids closed § Overall housekeeping q
SUPPLIER CONTAMINATION PREVENTION Tools for Reducing Risk Resources and Guidelines – Supplier Portal https: //buyat. ppg. com/suppliernetwork/frm. SNWeb. Portal. asp • • • PPG’s Maintenance Materials List (MRL) Crater Pre-Cleaning Procedure Silicone Valve Warning & Lube Free Letter Bulk and Bulk Solvent Prior Contents Requirements Change Notification Instructions and Form
SUPPLIER CONTAMINATION PREVENTION Questions? Comments?
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