8.

0 CONTAMINATION
CONTROL
QSB+
Train the trainer
How do you Contain Sediment?

Confidential - PSA GM Purchasing & Logistic Committee 1

 CONTAMINATION CONTROL
Procedures to contamination control, what are we searching for ?

Item QSB+ PCPA NSA Requirement Criteria of the Requirement

1) Failure modes related to contamination are considered in PFMEA, controls listed in
Control Plan.
2) Procedure developed which includes method defining sediment collection and system
to measure cleanliness.
3) Cleanliness results are documented and plotted on control chart.
Sediment is controlled with identification of
4) Control limits are utilized to trigger reaction plans.
possible risk areas for contamination as well as
CC1 X X X continuous measurement and monitoring of
5) At sand castings parts methods is defined to measure retained material (i.e. Tunk test)
before part reaches the final machining.
sediment level.

Confidential - PSA GM Purchasing & Logistic Committee 2

 CONTAMINATION CONTROL
Contamination Philosophy

Suppliers shall have procedures and work instructions for

Contamination Control where appropriate.
Work instructions may require: Note: All contamination
• Process monitoring failure modes shall be
• SPC or data collection included in PFMEA and
• Routine maintenance Control Plans under
“Process Controls”
• Preventative or predictive maintenance

Suppliers shall identify all areas/operations that could be affected by

contamination and identify the type of contamination in each area in
order to establish adequate controls

Confidential - PSA GM Purchasing & Logistic Committee 3

 CONTAMINATION CONTROL
Sediment
Definition: Sediment – small particles of material that will adversely
affect the function of the product.

• Particulate examples include contaminants like lint, dirt, sand,

plastic, machined chips etc.

• Examples of products that are adversely affected are:

– Engines
– Transmissions
– Brakes
– Steering Gears
– Fuel Modules
– Compressors

Confidential - PSA GM Purchasing & Logistic Committee 4

 CONTAMINATION CONTROL
Monitoring and measuring Sediment

• Establish an acceptable initial level of part/process cleanliness

• Establish appropriate processes and controls
• Require a procedure to measure part cleanliness at a specified
frequency
• Require recording/plotting of these measures
• Require control limits be utilized to trigger reaction plans
• Require corrective action to prevent nonconforming products

Monitoring of the process shall be included in Layered Process Audits

and non-conformances included as candidates for Fast Response.

Debris weight/size limits may be utilized to establish process upper control

limits or targets values in a component’s Statements of Requirements (SOR)
without formally being applied to an engineering drawing.

Confidential - PSA GM Purchasing & Logistic Committee 5

 CONTAMINATION CONTROL
Sediment reduction, what are we searching for ?

Item QSB+ PCPA NSA Requirement Criteria of the Requirement

Sediment reduction strategy is followed to
ensure proper functionality of equipment and
CC2 X processes designed to remove/prevent
sediment contamination.
1) Procedure/instruction to define and maintain method and frequency of checks to
ensure quality and cleanliness of:
- Metal Working Fluid System
- Fluid/Air Probes
- Work Station Cleanliness
- Dunnage and Part Storage
- Purchased parts
- Washer
- Debur.

Confidential - PSA GM Purchasing & Logistic Committee 6

 CONTAMINATION CONTROL
SEDIMENT REDUCTION STRATEGY
Process Controls:
Each manufacturing site shall define procedures for the method and frequency
of checks required to ensure proper functionality of equipment and processes
designed to remove/prevent sediment contamination:

• Parts Washers
• De-burr operations
• Metal working fluid controls
• Fluid / air probe flush station controls
• Dunnage and part storage systems
– Includes Purchased parts and materials and Finished Goods
• Work Station Cleanliness

Confidential - PSA GM Purchasing & Logistic Committee 7

 CONTAMINATION CONTROL
Clean Rooms, what are we searching for?

Item QSB+ PCPA NSA Requirement Criteria of the Requirement

1) Clean room protective clothing defined and enforced.
2) Positive pressure to stop outside air/contaminants from being drawn into the clean
room.
If clean room / area is required (due to sediment
3) Limited access by employee and enter/exit route to clean room are kept.
or painting requirement), special rules are
CC3 X X X utilized in order to minimalize risk of
4) Sticky mats or shoes protection to remove contaminants from footwear.
5) Control of Chemicals detrimental to the process.
contamination.

Confidential - PSA GM Purchasing & Logistic Committee 8

 CONTAMINATION CONTROL
Clean Rooms
If clean rooms are required as part of the manufacturing process, the
following set of requirements should be considered as best practices:
• Limited access to clean rooms by employees to limit exposure to
contaminants
• Clean room protective clothing defined and enforced (e.g. hair
nets, shoe covers, lint free lab coats, rags, gloves, etc.)
• Positive pressure to stop outside air/contaminants from being
drawn into the clean room.
• Air locks to enter/exit clean rooms
• Sticky mats to remove contaminants from footwear
• Atmospheric air quality monitoring per standard
• Anti-static devices (ESD) and verification to compliance prior to
entrance to the area as applicable. (e.g. ground straps, wrist
bands)
• Control of Chemicals detrimental to the process (e.g. windex,
lotions, fragrances, aerosol sprays, etc.)

Confidential - PSA GM Purchasing & Logistic Committee 9

 CONTAMINATION CONTROL
Dirt prevention in paint or part and extra parts contamination,
what are we searching for?

Item QSB+ PCPA NSA Requirement Criteria of the Requirement

1) Sources of dirt and foreign material as potential failure mode is considered in PFMEA.
2) Methods developed to prevent extra parts or materials that may fall into or stick to
products and verified through error proof verification and/or Layered Process Audits (e.g.:
sensor for masking used).
3) Procedure or instruction describes dirt control and prevention for key areas: People,
Process, Facility and Material.
Maintaining the processes to control and 4) Application of statistical method to monitor and control painting process such us dirt
prevent dirt in paint or part and foreign material count (SPC, U-chart), dirt identification (Pareto) etc.
CC4 X X X contamination. 5) Ensure proper functionality of equipment and processes designed to remove/prevent
dirt in paint or part.
6) Behaviour Instructions are defined and respected.

Confidential - PSA GM Purchasing & Logistic Committee 10

 CONTAMINATION CONTROL
Dirt in Paint
Definition and Philosophy:
• Dirt is an undesired foreign inclusion in the paint film caused by
disturbances in the paint process or operation.
• Dirt contamination as a group represents the greatest group of
paint defects.
• Sources should be minimized in all areas.
• Dirt control shall be continuous and ongoing to be effective.

Confidential - PSA GM Purchasing & Logistic Committee 11

 CONTAMINATION CONTROL
Dirt in Paint (Continued)

Confidential - PSA GM Purchasing & Logistic Committee 12

 CONTAMINATION CONTROL
Dirt in Paint (Continued)

Elements of an Effective Contamination Control

System:
• Make controls visible.
- Maintain a list of acceptable/unacceptable products in easily
accessed areas.
- Make the list easy to update.
- Make information clear & concise.
- Personal product lists displayed on posters in locker rooms
and employee areas.
• Clearly define those products that need to be totally eliminated
from the paint shop.
• Clearly define those products that can be used in the paint shop,
but should be kept away from product surfaces.

Confidential - PSA GM Purchasing & Logistic Committee 13

 CONTAMINATION CONTROL
Dirt in Paint (Continued)

Suppliers with painted product shall ensure that the paint operation
standards and maintenance schedules are adhered to. Whether the
process is internal or through Supply Chain Management.

This includes:
Process Monitoring such as
• Dirt count (SPC, U-Charts)
• Dirt identification (Pareto)
Process analysis and investigative techniques
Establish and maintain a Dirt Reference Handbook
Layered Process Audits and Communication of results

Confidential - PSA GM Purchasing & Logistic Committee 14

 CONTAMINATION CONTROL
Extra Parts
Definition: Parts or materials which fall into or stick to products which
are not intended as part of the finished product.

The manufacturing site shall include process controls to eliminate or

reduce extra parts:

• Utilize Rollovers and Dump Stations (Monitor findings)

• Parts assembled at prescribed location / rework station
• Magnetic wrench functionality
• Correct use of masks where the potential exists for parts to fall
into assemblies
• Rework operations to use same tools as primary operation
• Layered Process Audit to verify proper part storage
• Monitor findings of extra parts / Use data management /
Corrective Actions

Confidential - PSA GM Purchasing & Logistic Committee 15

 CONTAMINATION CONTROL
Contamination Control effectiveness, what are we searching
for?

Item QSB+ PCPA NSA Requirement Criteria of the Requirement

1) Sediment result monitored, reduction plan defined.
Targets are defined and followed to ensure 2) Layered audit and Process Specific audits results.
CCE X continuous contamination reduction activity 3) Internal or Customer issues related with cleanliness.
4) Pareto of defects for key sensible process (painting, metallization,...).

Confidential - PSA GM Purchasing & Logistic Committee 16

 CONTAMINATION CONTROL
What goes wrong ?

• Lack of Contamination Map which will indicate the critical process (affected
by contamination) and their controls
• Effects/Potential Causes related to contamination not addressed to PMEA
• Lack of Contamination Controls addressed in the Process Control Plan
• Issues related to contamination not escalated in a proper way
• No strategy to reduce the sediments
• Lack of special rules for clean room
• No results revision and /or countermeasures established by leadership

Confidential - PSA GM Purchasing & Logistic Committee 17