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Document PCI 02/25/09

The Powder Coating Institute

PCI 3000 Certification Program


Any copy, reproduction or unauthorized distribution of this material without written consent from The Powder Coating Institute is strictly prohibited.

Section1:Purpose&ObjectivesofPCI3000CertificationProgram 1.0Whatiscertification? 1.0.1 CertificationistheprocessbywhichThePowderCoatingInstitutehas createdanauditprogramtoevaluatethebusinesspractices,process elements,equipmentcapabilities,employeecompetenciesandquality controlcapabilitiesofacoatertoproduceahighqualitypowdercoated productwithahighdegreeofcustomersatisfaction. 1.0.2 Certificationbynomeansisadeterminationofthequalityofthe powdercoatedproductthatwillbeproduced.Itonlycertifiesthatthe coaterhasthecapabilitiesandcompetenciestoproduceahighquality powdercoatedproduct. 1.1Whycertification? 1.1.1 Thecertifiedcustomcoaterwillbenefitinthefollowingways. 1.1.1.1 UtilizetheexpertiseofthePCICertificationProcesstoevaluateand createamethodologytocontinuallyimproveandenhancetheir powdercoatingbusiness. 1.1.1.2 UtilizethePCIworldrenownedlogoandbenefitfromthehigh standardsthisimagebringstoelevatetheimageofthecertified coater. 1.1.1.3 Todifferentiateacertifiedcustomcoaterfromallothercustom coatersandgainaccesstobusinessopportunitiesrequiringPCI certifiedapplicators. 1.1.1.4 BerepresentedasacertifiedcoateronPCIwebsitesandPowder CoatedToughpublications. 1.2Whocanbecomecertified? 1.2.1 ThePCI3000certificationprogramisdesignedandofferedtoallcustom coatersapplyingpowdercoatingsandisnotexclusivelydesignedforPCI category5membercompanies.Membercompanieswillqualifyfor programdiscountsaslongastheyarePCImembersingoodstanding.

1.3WhatarethestandardsthatcanbeselectedforPCI3000Certification? 1.3.1 PCI3000AisacertificationforuseofpowdercoatingsonAluminum surfaces. 1.3.1.1 PCI3000A1isspecificallyforpowdercoatersrequiredtomeet AAMA2603performancestandards. 1.3.1.2 PCI3000A2isspecificallyforpowdercoatersrequiredtomeet AAMA2604performancestandards. 1.3.1.3 PCI3000A3isspecificallyforpowdercoatersrequiredtomeet AAMA2605performancestandards. 1.3.2 PCI3000SisacertificationforuseofpowdercoatingsonSteel surfaces. 1.3.3 PCI3000Hisacertificationforuseofpowdercoatingsonheat sensitivesubstrates;suchaswood,MDFand/orplastics. 1.3.4 PCI3000Fisacertificationforuseofpowdercoatingsonsurfacesthat requireafunctionalperformanceandmostcommonlyusemechanical pretreatment. 1.4Objectives 1.4.1 Theobjectiveofthiscertificationistooffercustomcoatersthe opportunitytodifferentiatethemselvesfromothercustomcoaters.The processisintendedtoimproveandenhancetheirabilitytoapply powdercoatings,optimizetheperformance,raisethestandardsofthe industryandrecognizethemeritsofacapablecustomcoater. 1.4.2 Offerstandardstoconsistentlyratepowdercoatingprocessesfocused on12mainareas. 1.4.2.1 Pretreatment 1.4.2.2 OvensandCuring 1.4.2.3 ApplicationArea 1.4.2.4 QualityControl 1.4.2.5 Training 1.4.2.6 Maintenance 1.4.2.7 CustomerSatisfaction 1.4.2.8 Safety 1.4.2.9 ProcessControl 1.4.2.10 QuotingandWarrantyPolicies

1.4.2.11 IncomingQualityControl 1.4.2.12 Loading,UnloadingandPackaging Section2:ProcessFlowforCertificationofPCI3000

Identify company management rep

Didthey pass?

Yes

Non conforma nce?

No

PCICertified

No Select standards Targetedaction plan

Yes Create CAR's InternalAudit

Traincompany representative

Sixmonth process improvement

Submit planto PCI No Passannual surveillance audit? Yes

Internal audit PCIReview No Confirm standards PCI approve plan? Yes

PCICertification Audit

Definitionandexplanationoneachstepoftheprocessflow. 1. ProcessFlow 1.1.IdentifyCompanyManagementRepresentative 1.1.1. ThispersonwillbetheresponsibleforworkingwithPCIthroughout thecertificationprocess.

1.1.2. Thispersonmusthaveagoodworkingknowledgeofpowdercoating andalloftheprocessesofapowdercoatingoperation. 1.1.3. Themanagementrepresentativeshouldhavemanagementduties andresponsibilitieswithinthecustomcoatersorganization 1.1.4. Ifthemanagementrepresentativeisnotadirectorwithinthe customcoaterorganizationhe/sheshouldreporttoadirectorofthe organization. 1.1.5. Shouldthemanagementrepresentativeleaveornolongerhavethe customcoatermanagementresponsibilitiesthecustomcoatermust providePCIwrittennoticeandareplacementmustbeselectedand scheduledtrainingwithin90daystomaintaincertification. 1.1.6. Thismanagementrepresentativewillberesponsibleforallinternal audits,allCorrectiveActionReports(CARs)aswellasanyTargeted ActionPlan(TAPs)necessarytogainormaintaincertification. 1.2.SelectStandard(s) 1.2.1. Whiletodaytherearefour(4)differentstandardsavailableitwillbe theresponsibilityofthemanagementrepresentativerepresentative todeterminewhichstandardsarebestsuitedforthecompany. 1.2.2. PCI3000Aisdesignedfortheapplicationofpowderonaluminum substrates.Thisisnotdesignedtoauthorizeorcertifyapowder coatertomeetAAMAspecifications. 1.2.2.1. ForcustomcoatersrequiredtomeetAAMAperformance standardsoneofthefollowingcategoriesmustbeselected. 1.2.2.1.1. PCI3000A1forAAMA2603 1.2.2.1.2. PCI3000A2forAAMA2604 1.2.2.1.3. PCI3000A3forAAMA2605 1.3.ManagementRepresentativeTraining 1.3.1. Theselectedmanagementrepresentativemusthavecompletedand passedPCItrainingbeforehe/shewillbequalifiedasthe representativefortheCertificationprogram. 1.3.2. Themanagementtrainingprocessisafulldaysessionwithaportion ofitinaclassroomandaportionofitintheplant.

1.3.3. Thistrainingprogramisdesignedformorethanonetoattend;ifthe customcoatingorganizationwouldliketotrainmorethanone personsotheyhaveabackupitisstronglysupportedbyPCI. 1.4.InternalAudit 1.4.1. Theinternalauditisdesignedforthecertifiedorganizationto evaluatetheirprocessandcompetenciesasitrelatestothe CertificationProgramtogainanunderstandingofwhatstandards theycouldpursueaswellaspreparethemforthePCIAudit. 1.4.2. Theinternalauditshouldalsobeameanstobetterunderstandtheir qualificationsandultimatelyknowwhenorifacompanyisa candidateforCertification. 1.5.ConfirmationofAppropriateStandards 1.5.1. Onceaninternalevaluationiscompleteandthestandardsare confirmedthenthecustomcoaterwillbereadytoordertheir CertificationauditfromPCIandanapplicationformmustbe completedandsenttoPCIforacceptanceandscheduling. 1.6.PCICertificationAudit 1.6.1. AllPCIauditsaredoneatthecustomcoaterssite. 1.6.2. AllPCIauditsareforonelocationonly. 1.6.3. Whileacertificationcanbeformultiplelines,alllinesmustbeatthe sameaddress. 1.6.4. Auditswillbeafulldaysessionandthecontentwillvary.The followingisatypicalagenda 1.6.4.1. ManagementMeetingandDiscoveryProcess 1.6.4.2. Planttourandvisualevaluation 1.6.4.3. Interviewsanddiscussionwithkeypersonnel 1.6.4.4. Reviewofrecordkeeping,logsandaudits 1.6.4.5. Systemandprocessevaluationinplanttoincludeallfacetsof thepowdercoatingprocess. 1.6.4.6. Closingmeetingwithmanagementandmanagement representative.

1.6.4.7. Thefollowupreportwiththescoringwillbedeliveredwithin twoweeks 1.7.TargetedActionPlan(TAP) 1.7.1. IfaTAPisrequireditmeansthatthescoreofthePCIauditdidnot meettheminimumscoretobecomecertified. 1.7.2. AlistofTAPswillbegiventothecustomcoaterandthe managementrepresentativemustestablishthenecessary improvementstomeettheminimumstandardandultimately becomecertified. 1.7.3. Nomorethansixmonthsareallowedforprocessimprovements 1.7.4. PCImustreviewtheseimprovementsbeforecertificationis authorized. 1.7.5. Typicallythesecanbehandledinaconferencecallbutinsomecases additionalfieldauditwillberequired. 1.8.NonConformances 1.8.1. TheseareimprovementopportunitiesfoundduringthePCIaudit process. 1.8.2. ThesearenotTAPstheyareimprovementsthatwerenotedand mustbeaddresshowever,thecustomcoaterstillmettheminimum scoretogaincertification. 1.9.CorrectiveActionReport(CARs) 1.9.1. PCIwillgivethecustomcoateralistofCARsthatmustbeworkedon andreportedbacktoPCIwithquarterlyupdatestomaintain certification. 1.9.2. InitiallycustomcoatermusthaveaCARimprovementplan 1.9.3. PCImustapproveallimprovementplans 1.9.4. PCIwillsupplyformstobeusedonallCARs 1.9.5. AlogmustbemaintainedforallCARsandmadeavailableforreviews attherequestofPCI. 1.10. PCICertification

1.10.1. OncethecustomcoaterhasachievedPCI3000Certification theywillbeallowedtouseapprovedPCIlogostopromote theirqualification. 1.10.2. ListedonPCIwebsiteasaCertifiedApplicator 1.10.3. Theabilitytopurchasemultipleproductstopromotetheir organizationasPCI3000Certified 1.10.4. GaintheabilitytoquotejobsthatrequirePCIcertification 1.11. OnGoingInternalAudits 1.11.1. Themanagementrepresentativewillberesponsibleforon goinginternalaudits. 1.11.2. Theseauditsmustbeperformedatleastquarterly. 1.11.3. WhilePCIdoesnotrequireasubmissionofquarterlyaudits, PCIwillrequestarecordoftheseauditstobereviewedduring anannualsurveillanceaudit. 1.11.4. Internalauditsarethemechanismtoworkoncontinuous improvementsinallaspectsofthepowdercoatingprocess. 1.12. SurveillanceAudits 1.12.1. Theseannualauditswillbeusedtomaintaincertification. 1.12.2. Thesewillbeusedtoreviewthesameareasthatfirstgained thecustomcoaterscertificationwiththeexpectationof improvementineveryarea. 1.12.3. Theseauditswillalwaysbedoneatthecustomcoatersfacility withasimilaragendatothePCICertificationAudit. 1.12.4. ManagementRepresentativemustbepresentandavailable duringthisaudit. 1.13. AddingStandardstoExistingCertification 1.13.1. Aformalrequestmustbemadetoaddadditionalstandardsto anexistingcertification. 1.13.2. Duringthesurveillanceauditisaverygoodtimetoadd standards,howeverthesecanbeaddedatanytime.

Section3:AuditAreasNeededforCertification

1. 3.1Pretreatment 1.1.Theexpectationsoftheauditarethatthepretreatmentprocesswillmeet theminimumstandardstosatisfythemarketserved. 1.2.Doesthecustomcoaterkeepappropriatelogstomaintainahighquality pretreatmentsystem? 1.3.Arepersonneladequatelytrainingtosupportthecurrentpretreatment system? 1.4.Ispretreatmentingoodworkingorder? 1.5.Multiplesampleswillbetakenandevaluatedfrompretreatmentsystem. 1.6.Multipleevaluationswillbemadepertainingtothepretreatmentsystem. 1.7.Ispretreatmentadequateforallsubstratesbeingcleaned? 1.8.Ispretreatmentadequateforallsoilsneedingtoberemoved? 1.9.Arethereanyroutinetestsconductedtoconfirmsatisfactory pretreatmentresults? 1.9.1. WhiteGlove 1.9.2. WaterBreakFree 1.9.3. Adhesion 1.9.4. Corrosion 1.9.5. CoatingWeight 2. 3.2OvensandCuring 2.1.Temperaturecontrols 2.2.Oventemperaturebalance 2.3.Cleanlinessofovens 2.4.Whocontrolsovensetpointsandwhenandhowaretheyauthorizedtobe changed? 2.5.Doescustomcoaterhaveanunderstandingofthecurecyclerequirements fordifferentmetalmasses? 2.6.Dryoffovencondition 2.7.Isboosterusedandhowaresetpointsdetermined?

2.8.Vestibulesconditionandfunctionality. 2.9.Exhaustcondition 2.10. WhilePCIwillnotcertifyanyovenforsafety,thesafetyelementsof theoven(s)willbereviewed. 2.11. Areburnerfiltersmaintained? 2.12. Isthereanypreventivemaintenancescheduleforburnersandfans? 2.13. Isthereanydocumentationroutineevaluationofovendryingand curecycletimesandtemperatures? 3. 3.3ApplicationArea 3.1.Cleanlinessofentireapplicationarea? 3.2.Isclimatecontrolledandhow? 3.3.Isthereadedicatedapplicationareaorroom? 3.4.Whatisthequalityoftheincomingcompressedair? 3.5.Isthecompressedairfromadedicatedsource? 3.6.Doesthecustomerreclaimoversprayedpowder? 3.7.Conditionofthecollectionsystem(s)? 3.8.Manualguns 3.8.1. Conditionofmanualguns 3.8.2. Outputofmanualguns(Kv) 3.8.3. Replacementpartsonhand? 3.8.4. Pumpconditions 3.8.5. Hopperconditions 3.8.6. Arehosesdedicatedtocolors 3.8.7. Lightinginapplicationareas 3.8.8. Groundatpointofapplication 3.8.9. Protectivewearofthoseinapplicationarea 3.8.10. Educationofthoseinapplicationarea 3.8.11. Applicationtechnique 3.8.12. Conditionandlengthofhosesand/ordeliverysystemtogun 3.8.13. Rejectratesforapplicationrelatedproblems 3.9.CollectionBooths 3.9.1. Conditionofcollectionsystem(s)

3.9.2. Iscolorchangeproceduredocumentedandisitcheckedandcross checked? 3.9.3. Educationsofthoseinvolvedincolorchangeand/orcleanupof booth. 3.9.4. Conditionofwallsofcollectionsystem 3.9.5. Conditionoffluidizedbedsoncollectionsystem? 3.9.6. Conditionofallgaugespertainingtocollectionsystem? 3.9.7. Crossdrafts? 3.9.8. Boothairvelocity. 3.9.9. Isvolume(CFM)ofcompressedairsufficienttosupportsystem? 3.9.10. Theuseofcompressedairasacleanuptool? 3.9.11. Pumpmaintenance? 3.9.12. Gunmaintenance? 3.9.13. Boothmaintenance? 3.9.14. Whereispowderstored? 3.9.15. Howispowderfedintosystem? Proximitytopotentialcontaminationcauses? 3.9.16. 3.9.17. Personnelonoffshiftsandtheireducationallevel? 3.9.18. Generalcleanlinessofboothandreclaimsystem. 4. IncomingQualityControl 4.1.Howareincomingpartsevaluatedandapprovedforcoating? 4.1.1. Arepartscountedandrecorded? 4.1.2. Arepartsevaluated? 4.1.3. Arepartsheldinastagingareabeforecoatingandhowlong? 4.1.4. Whocanrejectincomingpartsforcoating? 4.2.Howispowdercoatingevaluatedandapprovedforuse? 4.2.1. Ispowdercoatingloggedinbybatchnumber? 4.2.2. Ispowdercoatingsprayedbeforeuse? 4.2.3. Areretainskeptforpowercoatings? 4.2.4. Ispowderwellmaintainedinclimatecontrolarea? 4.2.5. HowareMaterialSafetyDataSheets(MSDs)maintained? 4.2.6. AreTechnicalDataSheets(TDSs)available? 4.2.7. Howispowderrotatedforuse?Isfirstin,firstout(FIFO)inventory managementsystemused? 4.2.8. Whocanrejectanincomingpowdercoating?

4.2.9. Whatarethestepstoassurereplacementwithoutuse? 4.2.10. Arecoatingsevaluatedinacontrolled,welllitareausinga consistentlightsource? 5. Training 5.1.Howispersonnelselectedforthepowderapplicationarea? 5.2.Istherealevelingsystem? 5.3.Isoutsidetrainingusedforallpowdercoatingpersonnel? 5.4.Areapplicatorscertifiedforjob? 5.5.Aresupervisorscertifiedforjob? 5.6.Whatistheoverallteamsunderstandingofthepowdercoatingprocess? 5.7.Isthereaninternaltrainingprogram? 6. Maintenance 6.1.Isthereaplannedmaintenanceprogram? 6.2.Areallnecessarysparepartsonhand? 6.3.Isthereanestablishedscheduleforcleanupandequipmentmaintenance? 6.4.Isthereanyroutinecontractormaintenanceperformedonequipment? 6.5.Whoisresponsibleforfilterinspectionandchange? 6.6.Arelogsmaintained? 7. CustomerSatisfaction 7.1.Doesthecustomcoaterhaveaprogramtoevaluatecustomersatisfaction? 7.2.DoesthecustomcoaterhaveaCustomerSatisfactionIndex? 7.3.Doesthecustomcoaterhaveaprocesstoimproveinareaswheretheyare deficientincustomersatisfaction? 7.4.Howarecomplaintshandled? 7.5.Arecomplaintscollectedorloggedin? 7.6.Iscustomersatisfactionpartofmanagementmeetings? 7.7.Isthereaphilosophyofcustomersatisfactionintheorganization? 8. Safety 8.1.Doesthecustomcoaterhaveasafetyculture?

8.2.Dotheyhavesafetymeetings? 8.3.Dotheyhaveasafetymanager? 8.4.Dotheytrackinjuries? 8.5.Dotheytrackunsafeconditions? 8.6.Ifapersonisinjuredonthejob,howisthatincidenthandled? 8.7.Isthereanunderstandingofrootcauseanalysisandisitused? 8.8.ArethererulesinplaceregardingtheuseofPersonalProtection Equipment(PPE)? 8.9.DopersonnelusePPEappropriately? 8.10. Howaresafetyrulesenforced? 8.11. Doesthecoaterusesafeandappropriatecleanupmethods? 9. ProcessControl 9.1.Doesthecustomcoaterhaveaprocesscontrolsystem? 9.2.Arejobsmonitoredthroughtheentirecoatingprocesswithajobtracker? 9.3.Onthejobtrackerarethefollowingnoted: 9.3.1. LineSpeed 9.3.2. Parthangingconfiguration 9.3.3. CureTemp 9.3.4. Pretreatmentrequirements 9.3.5. Qualitycontrolexpectations 9.3.6. Whatisareject? 9.3.7. PowderCoatingtobeused? 9.3.8. Typicalamountofcoatingtobeused? 9.3.9. FilmThicknessspecification? 9.3.10. Packagingneeds? 9.3.11. Partcount? 9.3.12. Completiondaterequested? 9.3.13. Anyuniquespecificationsorrequests? 9.4.Doescustomcoaterhaveanelectronictoolforprocesscontrol? 10.QuotingandWarrantyPolicies 10.1. HowareincomingRequestsforQuote(RFQs)handled? 10.2. Whocanquoteajob? 10.3. Howarequotedjobsmaintained?

10.4. Reviewtypicalquote? 10.5. Howlongarequotesgoodfor? 10.6. HowisprocessdeterminedfromRFQ? 10.7. Doescustomcoaterhaveawarrantyorguaranteeontheircoating? 10.8. Howisthisprogramandlanguagewrittentoprotectthecustom coater? 10.9. Doesthecustomcoaterhavecertificationfromanyother organizationthatmaysupporttheuseofwarrantiesorguarantees? 10.10. Howisthecostingofajobdeterminedforaquote? 10.11. Afterthejobisinhouseisthereacomparisonbetweenquotedcost andactualcost? 10.12. Howisthejobinhousecomparedtojobquoted? 10.13. Howareprototypesdone? 10.14. Areprototypeskeptforcomparisonpurposes? 11.FinalQualityControl 11.1. Howisqualitydefined? 11.2. Isthereaqualitymanual? 11.3. Arerejectsclearlydefinedandunderstood? 11.4. Whattestsareperformedonaroutinebases? Isthereanevaluationarea? 11.5. 11.6. Isthereconsistentlightingintheevaluationarea? 11.7. Istestequipmentcalibrated? 11.8. Whocanrejectparts? 11.9. Doescustomcoaterperiodicallydoacceleratedtesting? 11.10. Whattestsareperformedoutside? 11.11. Isretainmaintained? 11.12. Istheoriginalprototypemaintainedforcomparison? 12.Loading,UnloadingandPackaging 12.1. Howarepartsloaded? 12.2. Isthereaclearunderstandingofhangingconfiguration? 12.3. Isthereagoodgroundanddoloadersunderstandhowtocheck? 12.4. Aretherackswellmaintainedandfullyloaded? 12.5. Isconveyorcleanand/orcanitbeacauseforcontamination?

12.6. Arepartshunginaconsistentway? 12.7. Linedensity? 12.8. Arepartsevaluatedforsoilsorothercontaminations? 12.9. Canpartsberejectedatloadarea? 12.10. Howarepartshandledduringunloaded? 12.11. Howarepartsstackedorcollectedafterunloaded? 12.12. Istheretouchupatunloadarea,anddoesitmatch color/performance? 12.13. Cantheperson(s)unloadingpartsreject? 12.14. Howarepartspackaged? 12.15. Isthereconsistencyinpackaging? 12.16. Isthereaspecificationforpacking? 12.17. Canpackagingcausedamagetocoating? 12.18. Temperatureofpartsatpackaging? Section4:ManagementConsiderations,RecommendationandNon ConformancesFormsandTemplates 1. ManagementConsiderations 1.1.TheseareconsiderationsthatPCIwillofferthecustomcoaterthat couldbeconsideredforimprovements.Thesewillnotaffectthe coatersabilitytoobtaincertification. 2. Recommendations 2.1.Thesearetobeconsideredareaswherethecoatercanbecomemore efficient,effective,forcostreductions,energyconservation,waste management,improvedproductivity,reducerejectsetc. 2.2.Initiallytheserecommendationswillnotaffectcertification,however theexpectationisthattheseareasofimprovementwillbecomemore criticallyevaluatedinfutureauditsuptobeingconsideredasanon conformance. 3. NonConformance 3.1.AllnonconformanceareassightedduringthePCIcertificationaudit musthaveaCARassociatedwiththem. 3.2.Ifoneelementhasenoughnonconformancestoscorebelowthe minimumthresholdcertificationwillbedeniedandthecoatercan moveintoaTAPprogram.

3.3.Ifthecumulativescoreofalltheelementsfallsbelowtheminimum threshold,duetononconformances,thencertificationwillbedenied andthecoatercanmoveintotheTAPprocess.


The Powder Coating Institute Certification Program
(SAMPLE)CorrectiveActionPlan

Written Action Plan (xx/xx/xx) Out of Compliance Improvement Expectation Action to be Taken Time Frame

1.No Logs for Pretreatment System

Establish the use of a log for Pretreatment

Create a daily log with a check list for Pretreatment system and maintain for review.

Completion date May 1, 2009

2. Customer has evaluated customer satisfaction

Establish a customer Create methodology satisfaction program to track and record / Index customer satisfaction with a follow up program for complaints and review trends Add safety to Make safety a part of management business philosophy meetings as an agenda items and record accidents and review

April 2010

3. Safety is not a discussed at meeting nor are accidents recorded and evaluate.

Dec 31, 2009

ThePowderCoatingInstitute
2170BuckthornePlace,Ste.250 TheWoodlands,TX77380 Phone:(832)5850770Fax:(832)5850220 www.powdercoating.org

PCICERTIFICATIONPROGRAM
CorrectiveActionReport

CompanyName: PCIRep.(print) CompanyRep.(print)

CARNo.

CARName:
LevelofCorrectiveAction High Medium Low

DatetoComplete

NonCompliance

Improvement Expectation

Actiontobe taken

Actiontaken

Comments Reevaluationmeetingscheduledfor: CompanyRep.Signature PCIRep.Signature Completion Date Approved Date

X X

AdditionalComments

Section5:PCI3000ScoringMatrix
1. 3.1Pretreatment 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7. 1.8. 1.9.
FAILURE SCORE

Theexpectationsoftheauditarethatthepretreatmentprocesswillmeettheminimumstandardstosatisfythemarketserved. Doesthecustomerkeepappropriatelogstomaintainahighqualitypretreatmentsystem? Arepersonneladequatelytrainingtosupportthecurrentpretreatmentsystem? Ispretreatmentingoodworkingorder? Multiplesampleswillbetakenandevaluatedfrompretreatmentsystem. Multipleevaluationswillbemadepertainingtothepretreatmentsystem. Ispretreatmentadequateforallsubstratesbeingcleaned? Ispretreatmentadequateforallsoilsthatneedtoberemoved? Arethereanyroutinetestsconductedtoconfirmsatisfactorypretreatmentresults? 1.9.1. WhiteGlove 1.9.2. WaterBreakFree 1.9.3. Adhesion 1.9.4. Corrosion 1.9.5. CoatingWeight

50

86

n/a 10 7 7 7 7 10 7 n/a 3 7 7 7 7

2. 3.2OvensandCuring 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 2.10. 2.11. 2.12. 2.13. Temperaturecontrols Oventemperaturebalance Cleanlinessofovens Whocontrolsovensetpointsandwhenandhowaretheyauthorizedtobechanged? Doescoaterhaveanunderstandingofthecurecyclerequirementsfordifferentmetalmasses? Dryoffovencondition Isboosterusedandhowaresetpointsdetermined? Vestibulesconditionandfunctionality. Exhaust WhilePCIcannotandwillnotcertifyanyovenforsafetythesafetyelementsoftheoven(s)willbereviewed. Areburnerfiltersmaintained? Isthereanypreventivemaintenancescheduleforburnersandfans? Isthereanydocumentationroutineevaluationofovendryingandcurecycletimesandtemperatures? 50 85 10 10 7 5 5 7 n/a 5 7 10 5 7 7

3. 3.3ApplicationArea 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. 3.8. Cleanlinessofentireapplicationarea? Isclimatecontrolledandhow? Isthereadedicatedapplicationareaorroom? Whatisthequalityoftheincomingcompressedair? Isthecompressedairfromadedicatedsource? Doesthecustomerreclaimoversprayedpowder? Conditionofthecollectionsystem(s)? Manualguns 3.8.1. Conditionofmanualguns 3.8.2. Outputofmanualguns(Kv) 3.8.3. Replacementpartsonhand? 3.8.4. Pumpconditions 3.8.5. Hopperconditions 3.8.6. Arehosesdedicatedtocolors 3.8.7. Lightinginapplicationareas 3.8.8. Groundatpointofapplication 3.8.9. Protectivewearofthoseinapplicationarea Educationofthoseinapplicationarea 3.8.10. Applicationtechnique 3.8.11. Conditionandlengthofhosesand/ordeliverysystemtogun 3.8.12. Rejectratesforapplicationrelatedproblems 3.8.13. 7 5 3 10 3 n/a 7 7 7 5 7 7 3 7 10 7 10 7 7 7

126

3.9.

CollectionBooths 3.9.1. Conditionofcollectionsystem(s) 3.9.2. Iscolorchangeproceduredocumentedandisitcheckedandcrosschecked? 3.9.3. Educationsofthoseinvolvedincolorchangeand/orcleanupofbooth. 3.9.4. Conditionofwallsofcollectionsystem 3.9.5. Conditionoffluidizedbedsoncollectionsystem? 3.9.6. Conditionofallgaugespertainingtocollectionsystem? 3.9.7. Crossdrafts? 3.9.8. Boothairvelocity. 3.9.9. Isvolume(CFM)ofcompressedairsufficienttosupportsystem? 3.9.10. Theuseofcompressedairasacleanuptool? 3.9.11. Pumpmaintenance? Gunmaintenance? 3.9.12. 3.9.13. Boothmaintenance? 3.9.14. Whereispowderstored? 3.9.15. Howispowderfedintosystem? 3.9.16. Proximitytopotentialcontaminationcauses? Personnelonoffshiftsandtheireducationallevel? 3.9.17. 3.9.18. Generalcleanlinessofboothandreclaimsystem. 145 117 7 7 10 7 7 5 5 7 10 7 7 7 7 7 5 5 7 7

4. IncomingQualityControl Howareincomingpartsevaluatedandapprovedforcoating? 4.1.1. Arepartscountedandrecorded? 4.1.2. Arepartsevaluated? 4.1.3. Arepartsheldinastagingareabeforecoatingandhowlong? 4.1.4. Whocanrejectincomingpartsforcoating? 4.2. Howispowdercoatingevaluatedandapprovedforuse? 4.2.1. Ispowdercoatingloggedinbybatchnumber? 4.2.2. Ispowdercoatingsprayedbeforeuse? 4.2.3. Areretainskeptforpowercoatings? 4.2.4. Ispowderwellmaintainedinclimatecontrolarea? 4.2.5. HowareMaterialSafetyDataSheets(MSDs)maintained? 4.2.6. AreTechnicalDataSheets(TDSs)available? 4.2.7. Howispowderrotatedforuse?Isfirstin,firstout(FIFO)inventorymanagementsystemused? 4.2.8. Whocanrejectanincomingpowdercoating? 4.2.9. Whatarethestepstoassurereplacementwithoutuse? 4.2.10. Arecoatingsevaluatedinacontrolled,welllitareausingaconsistentlightsource? 4.1. 40
5. Training 5.1. 5.2. 5.3. 5.4. 5.5. 5.6. 5.7. Howispersonnelselectedforthepowderapplicationarea? Istherealevelingsystem? Isoutsidetrainingusedforallpowdercoatingpersonnel? Areapplicatorscertifiedforjob? Aresupervisorscertifiedforjob? Whatistheoverallteamsunderstandingofthepowdercoatingprocess? Isthereaninternaltrainingprogram? 35 57 10 5 7 10 10 10 5

10 10 5 5 5 3 3 10 10 3 7 5 3 7 86

6. Maintenance 6.1. 6.2. 6.3. 6.4. 6.5. 6.6. Isthereaplannedmaintenanceprogram? Areallnecessarysparepartsonhand? Isthereanestablishedscheduleforcleanupandequipmentmaintenance? Isthereanyroutinecontractormaintenanceperformedonequipment? Whoisresponsibleforfilterinspectionandchange? Arelogsmaintained? 30 42 10 5 7 5 5 10

7. CustomerSatisfaction 7.1. 7.2. 7.3. 7.4. 7.5. 7.6. 7.7. Doesthecustomerhaveaprogramtoevaluatecustomersatisfaction? DoesthecustomerhaveaCustomerSatisfactionIndex? Doesthecustomerhaveaprocesstoimproveinareaswheretheyaredeficientincustomersatisfaction? Howarecomplaintshandled? Arecomplaintscollectedorloggedin? Iscustomersatisfactionpartofmanagementmeetings? Isthereaphilosophyofcustomersatisfactionintheorganization? 25 51 10 5 7 7 5 7 10

8. Safety 8.1. 8.2. 8.3. 8.4. 8.5. 8.6. 8.7. 8.8. 8.9. 8.10. 8.11. Doesthecustomerhaveasafetyculture? Dotheyhavesafetymeetings? Dotheyhaveasafetymanager? Dotheytrackinjuries? Dotheytrackunsafeconditions? Ifapersonisinjuredonthejob,howisthatincidenthandled? Isthereanunderstandingofrootcauseanalysisandisitused? ArethererulesinplaceregardingtheuseofPersonalProtectionEquipment(PPE)? DopersonnelusePPEappropriately? Howaresafetyrulesenforced? Doesthecoaterusesafeandappropriatecleanupmethods? 36 73 10 7 7 5 3 5 5 7 10 7 7

9. ProcessControl Doesthecustomerhaveaprocesscontrolsystem? Arejobsmonitoredthroughtheentirecoatingprocesswithajobtracker? Onthejobtrackerarethefollowingnoted: 9.3.1. LineSpeed 9.3.2. Parthangingconfiguration 9.3.3. CureTemp 9.3.4. Pretreatmentrequirements 9.3.5. Qualitycontrolexpectations 9.3.6. Whatisareject? 9.3.7. PowderCoatingtobeused? 9.3.8. Typicalamountofcoatingtobeused? 9.3.9. FilmThicknessspecification? Packagingneeds? 9.3.10. Partcount? 9.3.11. Completiondaterequested? 9.3.12. Anyuniquespecificationsorrequests? 9.3.13. Doescustomerhaveanelectronictoolforprocesscontrol? 9.4. 9.5. 9.1. 9.2. 9.3. 10 7 7 5 5 5 5 5 5 10 5 7 5 7 7 10 5 60 100

10. QuotingandWarrantyPolicies 10.1. 10.2. 10.3. 10.4. 10.5. 10.6. 10.7. 10.8. 10.9. 10.10. 10.11. 10.12. 10.13. 10.14. HowareincomingRequestsforQuote(RFQs)handled? Whocanquoteajob? Howarequotedjobsmaintained? Reviewtypicalquote? Howlongarequotesgoodfor? HowisprocessdeterminedfromRFQ? Doescustomerhaveawarrantyorguaranteeontheircoating? Howisthisprogramandlanguagewrittentoprotectthecustomer? Doesthecustomerhavecertificationfromanyotherorganizationthatmaysupporttheuseofwarrantiesorguarantees? Howisthecostingofajobdeterminedforaquote? Afterthejobisinhouseisthereacomparisonbetweenquotedcostandactualcost? Howisthejobinhousecomparedtojobquoted? Howareprototypesdone? Areprototypeskeptforcomparisonpurposes? 43 86 7 5 7 7 5 5 7 5 5 5 7 7 7 7

11.

FinalQualityControl 11.1. 11.2. 11.3. 11.4. 11.5. 11.6. 11.7. 11.8. 11.9. 11.10. 11.11. 11.12. Howisqualitydefined? Isthereaqualitymanual? Arerejectsclearlydefinedandunderstood? Whattestsareperformedonaroutinebases? Isthereanevaluationarea? Isthereconsistentlightingintheevaluationarea? Istestequipmentcalibrated? Whocanrejectparts? Doescustomerperiodicallydoacceleratedtesting? Whattestsareperformedoutside? Isretainmaintained? Istheoriginalprototypemaintainedforcomparison? 60 91 10 10 10 10 10 7 7 5 5 5 5 7

12. Loading,UnloadingandPackaging 12.1. 12.2. 12.3. 12.4. 12.5. 12.6. 12.7. 12.8. 12.9. 12.10. 12.11. 12.12. 12.13. 12.14. 12.15. 12.16. 12.17. 12.18. Howarepartsloaded? Isthereaclearunderstandingofhangingconfiguration? Isthereagoodgroundanddoloadersunderstandhowtocheck? Aretherackswellmaintainedandfullyloaded? Isconveyorcleanand/orcanitbeacauseforcontamination? Arepartshunginaconsistentway? Linedensity? Arepartsevaluatedforsoilsorothercontaminations? Canpartsberejectedatloadarea? Howarepartshandledduringunloaded? Howarepartsstackedorcollectedafterunloaded? Istheretouchupatunloadarea,anddoesitmatchcolor/performance? Cantheperson(s)unloadingpartsreject? Howarepartspackaged? Isthereconsistencyinpackaging? Isthereaspecificationforpacking? Canpackagingcausedamagetocoating? Temperatureofpartsatpackaging? 65
650

7 10 10 10 5 10 5 5 7 5 5 5 5 5 7 7 7 5 113
1000

Section6:PCI3000Logo