BENZ外观检查标准.doc

Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface ExteriorAuthor: Michael FrischRelease Date: 20081210Released by: Michael FrischEffective from: 20081210Effective until:Guideline DefinitionObjective and Purpose:Process:Scope:The guideline definition is used for evaluation ofpainted and chromium plated surfaces of exterior addon components of automobiles from a customersperspectiveQuality Management / AssuranceMBC overallFurther applicable documents/Appendix: MSPMK9CQ Visual Color AssessmentIF5M9XFD Color Measurement374RNV14 PPFDBL 5416, 7399, MB Special TermsVDA 6.3, VDA 16, DIN EN 124641Reference Samples Catalogue (available withMBC/QKE)Doc.Nr.: 30.11.2008EWBXMNYV Hard copy is not subject to reviewVersion: 3.0 servicePage1Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface ExteriorContentGuideline Definition1. ABBREVIATIONS .32. DESCRIPTION .43. SCOPE.44. RESPONSIBILITIES .45. GUIDELINE DEFINITION .55.1 CONDITIONS OF ASSESSMENT . 55.2 OPTICAL CHARACTERISTICS OF COMPONENTS.75.3 VIEWING ZONE CLASSIFICATION .85.4 GUIDELINE FOR SURFACE DEFECTS GENERAL REQUIREMENTS. 125.4.1 GUIDELINE FOR PAINTED SURFACES. 135.4.1.1 GUIDELINE FOR COUNTABLE TYPES OF DEFECTS ON PAINTED SURFACES. 135.4.1.2 POSTPAINTING OF COMPONENTS WITH THE SUPPLIER. 145.4.1.3 LIST OF ALL TYPES OF DEFECTS. 155.4.2 GUIDELINE FOR CHROMIUM PLATED SURFACES . 205.4.1.1 GUIDELINE FOR COUNTABLE TYPES OF DEFECTS ON CHROMIUM PLATED SURFACES . 205.4.2.2 LIST OF ALL TYPES OF DEFECTS. 215.5 REGULATING REFERENCE SAMPLES . 255.7 EVALUATION SYSTEM FOR THE ASSESSMENT OF SURFACE DEFECTS .275.8 EVALUATION SITE FOR REFERENCE SAMPLES. 296.2 ADDITIONAL PICTURES FOR PAINTED SURFACE DEFECTS . 336.3 ADDITIONAL PICTURES FOR CHROMIUM PLATED SURFACE DEFECTS .34Doc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage2Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface Exterior1. AbbreviationsASCoverCPADAIDBLEPFuVoHBKLHMBC/QMBC/PMFPAPAPPPFPro(x)SUVSZVAGuideline DefinitionTowing Eye CoverCustomer Product AuditDaimler AGDaimlerBenz Shipping InstructionCar ProductionFunction RegulationManualComponent SpecificationsMercedesBenz Cars / QualityMercedesBenz Cars / ProductionGuideline DefinitionProduct AuditProcess ScheduleProduction process and ApprovalProduction TestingSport Utility VehicleViewing ZoneProcess InstructionDoc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage3Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface Exterior2. DescriptionGuideline DefinitionThe guideline definition is used for evaluation of painted and chromium plated surfaces of exterioraddon components of automobiles from a customers perspective.Additionally, it is used for a clear definition of decorative product surfaces (“visual appeal” ofsurfaces) to avoid process faults with customers and suppliers owing to “fuzzy” or missing guidelines.Furthermore, the procedure for the adaptation of reference samples is described.In derogation of this guideline definition, within the framework of component sampling, a morestringent guideline in accordance with state of the art can be agreed upon.3. ScopeMercedesBenz Cars (not applicable to smart)4. ResponsibilitiesFor complying with these guideline definitions, both the DAI areas in charge (see Scope) as wellas suppliers for painted and chromium plated components are responsible.It is the responsibility of MBC/QK to define the guideline.Doc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage4Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface Exterior5. Guideline Definition5.1 Conditions of AssessmentAssessing the ComponentGuideline DefinitionThe assessment of the addon component is to be carried out in accordance with the installationangle and the position on the vehicle or its function condition in mounting position.Fig. 5.1: Retaining racks for the assessment of the component in mounting positionApproach of AssessmentAdaptations of reference samples take place at the audit site of the overall vehicle audit. Theaudit site is described in the PA method manual (Manual 1051YEHJ). The procedure is describedin chapter 5.6During the assessment the following conditions are to be observed:a) Brightness and Color Temperatureb) Angle of IncidenceDaylight or D65 artificial light with a color temperaturecorresponding to fluorescent lamp DL 65 (Luminance:min. 1000 lux)Note:It must be acknowledged that certain characteristicscannot be detected under artificial light or day lightand vice versa. In this case separate guidelines are tobe bindingly defined.When designing an audit site or if the audit takes placeat the production site, the artificial light is to beinstalled in a 120 cm distance above the test object.Doc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage5Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface ExteriorGuideline Definitionc) Orientation of the LightFloorViewing distance:Viewing period:Assessment position:At the audit site the components are to be arranged inaccordance with the position on the vehicle. Thevehicles are to be positioned at the audit site inaccordance with Fig. 5.8 in chapter 5.8.LightgreyAssessment of the parts is to be carried out withoutoptical aids (such as mirrors, lamps, magnifying glassetc.). For that the assessor is to keep a normaldistance of about 50 70 cm to the test object(outstretched arm) (Fig.: 5.2)For adaptations of reference samples the followingapplies:Approx. 15 seconds per error patternFor sampling the times mentioned below are apply asapproximate values. The following viewing periods areto be considered per area:Viewing Area Amax: 5 s / 400 cm2Viewing Area B/C:max: 3 s / 400 cm2Generally, the upper viewing period limit for eachcomponent is max. 60 seconds.Assessment Position 1:In Assessment Position 1 the component is assessedby a person standing (Fig.: 5.2). During assessment theaddon component is either on the vehicle or on a rackin the position of the vehicle.Assessment Position 2:In Assessment Position 2 the component is assessedby a person crouching. For that the component to beassessed should be at least at eyelevel. (Fig. 5.2).Doc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage6Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface ExteriorGuideline DefinitionFig. 5.2: Assessment position and viewing angle using the example of a bumperLegend:Assessment Position 1Assessment Position 2Viewing angle5.2 Optical Characteristics of ComponentsThe components are to have a uniform visual appearance over the entire surface area and meetthe design requirements as well as the release sample. If need be it is possible to definereference samples between the supplier and QM departments.Essential surface characteristics to be assessed are:Surface:Color:Structure:Brightness:According to KLH, FuVo, DBL and this guideline definitionAccording to VA “MSPMK9CQ visual assessment of color”According to VA “IF5M9XFD color measurement”According to VA “MSPMK9CQ visual assessment of color”In accordance with the back of the reference color paletteDoc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage7Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface ExteriorGuideline DefinitionDefinitions differing from this guideline with regard to surface characteristics are to be agreedupon directly by the customer and the supplier.In addition, it is possible that for addon components with mounting positions which can beconsidered extremely critical, component specific guideline definitions are available, in whichcase requirements are to be obtained from the customer. In accordance with thesespecifications the supplier will then prepare a component specific guideline definition.If references samples are defined beyond this guideline definition, they will be documentedduring sampling or PPF reporting. The sample with a maximum defect characteristic will bereleasedatestamped and signed by everyone involved.5.3 Viewing Zone ClassificationClassifying component surfaces into assessment areas, so called viewing zones is to acknowledgethe different visibility and weight of defects. The classification depends on the shape andmounting position of the component. An area is limited to the components boundaries such asthe contour of the bumper.EP includes the reference “Surface Requirements according to the Guideline Definition Surface Exterior” into the KLH and component drawing. The viewing areas agreed upon by both supplierand MBC/QKE will be documented in the component drawing by EP. To ensureunambiguousness it proved beneficial that the supplier provides an additional detailed ABCdescription of the viewing area.The following graph shows the standard color to be used for the viewing areas:Viewing Zone AViewing Zone BViewing Zone CViewing Zone DTable 5.1: Standard colors for the Viewing AreasDoc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage8Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface ExteriorViewing Zone AGuideline DefinitionComprises all areas directly positioned towards the assessor, i.e. all upward or vertically facingareas. In these areas irregularities are especially disturbing and immediately detectable.Viewing Zone BComprises all areas that are not in immediate view, i.e. all downward facing areas and areaswhere irregularities are not very disturbing or easily detectable.Viewing Zone CComprises all covered and indirect areas that are either outside the viewing area or viewedhardly ever or only for a short period of time or areas that are covered by lids.Viewing Zone DComprises all covered and indirect areas that are either outside the viewing area or viewedhardly ever or only for a short period of time or areas that are covered after mounting. Paintingthese areas is carried out exclusively for decorative reasons. During chromium plating theseareas are being deposited for procedural reasons.Minimum Requirements for Areas from Viewing Zone DPainted SurfaceThe area must be painted uniformly or the paint film must be homogenous preventing thesubstrate form shining through the paint. The paint film must be adhesive. Paint requirements inaccordance with DBL are not tested. (e.g. chemical and UV resistance).Chromium Plated SurfaceThe back of the component corresponds to Viewing Zone D. Corrosion resistance must beallowed for. No demands in view of optical characteristics are being made.Doc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage9Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface ExteriorPrinciple depiction of a bumper coveringGuideline DefinitionFig. 5.3: Viewing zone classification using the example of a bumper coveringVehicle specific features are to be taken into consideration in coordination with the EP andMBC/QKE.Using the example of a bumper covering it is to be demonstrated that a detailed definition isimperative.The Appendix depicts further standards for the component specific viewing zone classification.Fig. 5.4: Classification criteria, addon componentLegend:Tangent at component surface; Positive angle between tangent and yzlevel; xylevel withinvehicle mesh; yzlevel within vehicle mesh; negative angle between tangent and yzlevelDoc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage10Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface ExteriorGuideline DefinitionThe following shows the approach of a contourconsidering viewing zone classification for anykind of geometry. Example for an angle:0 90(Viewing Zone A)(20) 0(Viewing Zone B)(90) (20)(Viewing Zone C)Fig. 5.4: Viewing Zone Classification addon componentVariations from the MethodThe roughly classification of the viewing zones is carried out according to the above mentionedmethod. For refining, the features according to concept must be observed. It is to be taken intoconsideration, whether the component while using the vehicle can be viewed from differentpositions. Here, the mounting position is the main criteria for the decision.In exceptional cases it is possible to define areas with low negative inclination as a Viewing ZoneA. This can include extensive areas obtaining large Zlevels, are very visible and are, from acustomers perspective, to be classified as critical. (e.g. SUVs)Surfaces with a higher viewing zone can be classified SZ “C” if they are visible to the assessorthrough reflections in other components (e.g. chrome flakes of radiator grills) or during use ofthe vehicle (e.g. opening of lids).Surfaces that do not require special specification in accordance with the shipping instructionscorrespond to SZ “D”.Conspicuous component characteristics (eyecatcher) can be sectioned, differing from generalmethods, into a more critical viewing zone; e.g. ASCover: If the ASCover is positioned in SZ“B”, it must be classified as SZ “A” including a 30 mm circumferential range.Doc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage11Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface ExteriorGuideline Definition5.4 Guideline for Surface Defects General RequirementsPossible causes can be the application, the material, mechanical or environmental influences.Defects are being assessed in accordance with their distinctive feature. The overall opticalappearance of the defect is crucial to the evaluation. Imperfections, perceived within the givenviewing period are to be compared to the acceptance criteria.Functionimpairing defects are not permitted (z. B. DBL, VA) or reliability tests (e.g. KLH andFuVo) must be fulfilled.Defects will be allotted to the corresponding viewing zones ensuring a differentiatedassessment.Inclusion are not to be sharpedged, appearing differently colored or bright (the latter especiallyapplies to chromium plated surfaces). Furthermore, no polishing fabric or microfiber cloth is tostick to the component surface.The following belong to generally forbidden defects in viewing zones “A” to “C”:1. Dents / Bumps2. Sink Marks3. Waviness4. Burr5. Mold Parting Lines6. Bonding Lines and7. StreaksNonimpairing surface defects are permitted in viewing zone “D”.In exceptional cases, unavoidable caused by concept defects can be classified via the referencesamples (chapter 5.6).Permissibility of flat and countable types of defects is defined in the following chapters. In theevent of a dispute daylight will decide.Doc.Nr.: 30.11.2008EWBXMNYVVersion: 3.0Hard copy is not subject to reviewservicePage12Translation by N.Gartz / Ganatec Services DAIMLERAbstractGuideline Definition Surface Exterior5.4.1 Guideline for Painted SurfacesGuideline Definition5.4.1.1 Guideline for countable Types of Defects on Painted SurfacesMeasuring the Size of the DefectDia