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16

Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

Page Type of characteristic Page Type of characteristic


No. 1: Offset No. 28: Various polishing defects

No. 2: Burn marks No. 28a: Stippling


2 9
No. 3: Dents No. 28b: Dull areas

No. 4a: Bubbles No. 28c: Holograms

No. 4b: Pitting No. 28d: Polishing flecks

No. 5: Impression marks No. 29: Polishing "fish" / "comet tails"


3 10
No. 6: Anodising splits No. 30: Polishing streaks

No. 7: Colour misting No. 31: Pores

No. 8: Colour differences No. 32: Indications of seams / seam-welds

No. 9: Swollen edges No. 33: Scour marks


4 11
No. 10: Flecks No. 34: Step marks (linear traces of rolling)

No. 11: Flash on tool split line No. 35: Striations

No. 12: Differences in sheen No. 36: Graininess

No. 13: Flash / burrs No. 37: Corrugations


5 12
No. 14: Grittiness No. 38a: Cloudiness/ fogging/ streaks

No. 15: Hairline splits No. 38b: Streaks caused by moisture / air

No. 16: Contact / gripping points No. 39: Differences in coating thicknesses

No. 17: Scratches; grooves 13 No. 40: Sink marks


6
No. 18: Paint runs No. 41: Converging flow marks

No. 19: Lens-like paint marks No. 42: Sucker marks

No. 20: Thin coating areas No. 43: Seam welds

No. 21: Macro-splits No. 44: Moisture inclusions


7 14
No. 22: Pin-holes No. 45: Holes

No. 23: Nickel patches No. 46: Alignment gap / offset

No. 24: "Orange-peel" effect No. 47: Patch marks

No. 25: Oxide lines No. 48: Jagged knife edges


8 15
Source Legend: No. 26: Pimpling / inclusions No. 49: Differences in structure and texture
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting No. 27: Pigmentation problems
9) Polishing 15) Metal die-castingNo. 50: Compressed folds
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing
No. 51: Paint residues
16 Page 1 of 17
No. 52: Burn marks
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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 1: Offset
Data:
Definition: Misalignment where parts are structured (for example,
by vulcanisation or over-moulding).
Process allocation: 5, 8, 12, 13, 15
Examples of permissible characteristic features:
Zone A: Visible and detectable by touch +/- 0.3 mm
Zone B: +/- 0.7 mm

No. 2: Burn marks


Data:
Definition: Matt / crumbly appearance to surface, caused by
dendritic separation in the limit current area (referred
to as "buds" when they are large).
Process allocation: 1, 6
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 3: Dents
Data:
Definition: Flat bubble-like depressions, caused by high pressure.
Process allocation: 6, 8 -16
Examples of permissible characteristic features:
Zone A: Not acceptable if visible at a distance of > 800 mm
Zone B: Not acceptable if visible at a distance of > 1200 mm

No. 4a: Bubbles


Data:
Definition: Generally round, even protrusions (hollow inside).
Process allocation: 2, 3, 6, 7, 13
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 4b: Pitting


Data:
Definition: Generally circular, crater-like depressions in the top
coat or intermediate coats. Typified by raised edges.
Process allocation: 2, 3, 6, 7, 13

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 5: Impression marks


Data:
Definition: Irregularly distributed, slight spots or depressions to
the surface, over very limited areas, caused by the
compression of foreign bodies.
Process allocation: 6, 8, 9, 10, 12, 13, 16

Examples of permissible characteristic features:


Zone A: D = 0.7 mm max. 2 depressions within a spacing of 400 mm
Zone B: D = 1.0 mm max. 4 depressions within a spacing of 300 mm

No. 6: Anodising splits


Data:
Definition: Micro-splits : small, linear features in the anodising
coating, caused by excessive local deformation of the
component or excessive coating build-up during
anodizing.
Process allocation: 1
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 7: Colour misting


Data:
Definition: Fine, dust-like paint particles on the surface, not
distributed in a homogenous manner in the paint film;
drop-like paint particles distributed over the paint film.
Process allocation: 3, 13
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Acceptable

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 8: Colour differences


Data:
Definition: Colour deviation on a surface by comparison with the
neighbouring surface or reference sample. This results
from :
(a) materials
(b) process
(c) subjective impression : saturation; brightness; purity;
level of sheen; depth; surface structure.

Process allocation: 2, 3, 6, 13
Examples of permissible characteristic features:
Zone A: Deviation refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 9: Swollen edges


Data:
Definition: A thickening of paint coatings (bulging) on edges of
components, such as are caused by surface tensions.
The effect correlates primarily with the edge radius
and/or the position of the component during the
process.
Process allocation: 2, 3, 6, 13
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Acceptable

No. 10: Flecks


Data:
Definition: Sharply delineated, local dulling of the surface, caused
for example, by dirt / corrosion in spots or larger areas,
or drying flecks.
Process allocation: 1, 2, 3, 6, 7, 13
Examples of permissible characteristic features:
Zone A: Not acceptable
Zone B: Not acceptable

No. 11: Flash on tool split line


Data:
Definition: Flash which can occur where there is a mismatch
between parts of a tool or sliders (e.g., plastic residues
on injection-moulded parts).
Can also be caused by wear and overflows.
Process allocation: 5, 6, 13
Examples of permissible characteristic features:
Zone A: Max. +0.3 mm
Zone B: Max. +0.5 mm

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 12: Differences in sheen


Data:
Definition: The sheen (or gloss) differs from that of the (master)
sample or specification figure on some areas or over
complete surfaces.
Process allocation: 1, 3, 6, 7, 13
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 13: Flash / burrs


Data:
Definition: Sharp-edged projection of edge zones from earlier
process (e.g., stamping burrs on cut edges; flash on
plastic mouldings; paint grit).
Process allocation: 2, 3, 5, 8, 15
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 14: Grittiness


Data:
Definition: Visual (optical) effect which can occur by diffuse
reflection on interfaces between different structures
(e.g., etched granularity).
Process allocation: 1, 3, 6

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 15: Hairline splits


Data:
Definition: Extremely fine lines of damage.
Process allocation: 3, 6, 10, 13

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 16: Contact / gripping points


Data:
Definition: Small areas, usually as spots where paint / coating is
missing (in an area not normally visible), caused by
suspension clamps, contact with painting frames, etc.).
Process allocation: 1, 2, 6, 7

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 17: Scratches; grooves


Data:
Definition: Lines of damage, caused by inappropriate
handling.(e.g., when removing parts from the tool).
Process allocation: 5, 6, 8, 10, 13, 16

Examples of permissible characteristic features (longitudinal):


Zone A: L < 4mm, W < 0,5mm
Max. 2 scratches within 300 mm
Zone B: L < 10mm, W < 0,7mm
Max. 4 scratches within 200 mm

Examples of permissible characteristic features (transverse):


Zone A: Not acceptable
Zone B: Not acceptable

No. 18: Paint runs


Data:
Definition: Tracks of paint in the top coat or in an undercoat, on
vertical surfaces (generally in the vicinity of grooves,
rounded sections, folds or piercings).
Process allocation: 2, 3, 13

Examples of permissible characteristic features:


Zone A: Not acceptable
Zone B: Acceptable

No. 19: Lens-like paint marks


Data:
Definition: Distortion in paint surface which can be seen but not
felt: paint runs / streaks in the early stages.
Process allocation: 2, 3, 13

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 20: Thin coating areas


Data:
Definition: Inadequate top coating (the substrate can be seen
through the surface coating)
Process allocation: 2, 3, 7, 13

Examples of permissible characteristic features:


Zone A: Not acceptable
Zone B: Refer to MTP sample(s)

No. 21: Macro-splits


Data:
Definition: Splits in the galvanic coating, caused by deformation
or stresses in the component.
Process allocation: 1, 6

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 22: Pin-holes


Data:
Definition: Very small cratering (see No. 4b); also micro-pores.
Process allocation: 2, 3, 6, 7, 13

Examples of permissible characteristic features:


Zone A: A frequency of max. 5 pin-holes
2
over 4 cm permitted
Zone B: Pin-holes permitted

No. 23: Nickel patches


Data:
Definition: Yellowish places in the contact area and in areas
where the current density is low.
Process allocation: 6

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 24: "Orange-peel" effect


Data:
Definition: A rough or wave-like appearance of a painted surface
which may contain a texture; a grained paint finish with
the structure of an orange peel.
Process allocation: 2, 3, 6, 13

Examples of permissible characteristic features:


Zone A: A fine structure is permitted – refer to limit sample for
severity and surface area.
Zone B: A coarse structure is permitted – refer to limit sample
for severity and surface area.

No. 25: Oxide lines


Data:
Definition: Identification :
Streaks caused by oxide inclusions and/or oxide lines.
Description & effects :
Pencil-like, white or grey lines in the direction in which
the part was formed. The degree of visibility depends
on the type and quantity of oxide inclusions.
Process allocation: 11

Examples of permissible characteristic features:


Zone A: Not permitted if structures visible at a distance of > 800 mm.
Zone B: Not permitted if structures visible at a distance of > 1200 mm.

No. 26: Pimpling / inclusions


Data:
Definition: Contamination within the surface, such as dust or fluff,
which protrudes in some areas through the coating or
growths causing problems in the build-up of coats.
Process allocation: 1 -7, 15

Examples of permissible characteristic features:


Zone A: See Section 10.2
Zone B: See Section 10.2

No. 27: Pigmentation problems


Data:
Definition: Disorientation of pigments
(e.g., metal flakes).
Process allocation: 2, 3

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
No illustration available
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 28: Various polishing defects


Data:
Definition: Collective category for defects not often encountered /
which form a small percentage of defects
Stippling: Polygonal, flecked areas caused by
material residues which have been polished in.
Dull areas: These occur following electrolytic sheening and
are caused by excessive local heating; also
surfaces areas which have not been sufficiently
polished.
Holograms: Polishing defects with a 3-dimensional effect.
These occur particularly with dark paint colours.
Polishing flecks: Restricted circular areas with a much
smoother surface than the surroundings

Process allocation: 6, 9, 13, 16

Examples of permissible characteristic features:


Zone A: Not permitted if visible at a distance of > 800 mm.
Zone B: Not permitted if visible at a distance of > 1200 mm.

No. 28a: Stippling


Data:
Definition: Polygonal, flecked areas caused by material
residues which have been polished in.
Process allocation:

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
No illustration available
Zone B: Refer to MTP sample(s)

No. 28b: Dull areas


Data:
Definition: These occur following electrolytic sheening and are
caused by excessive local heating; also surfaces areas
which have not been sufficiently polished.
Process allocation:

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 28c: Holograms


Data:
Definition: Polishing defects with a 3-dimensional effect. These
occur particularly with dark paint colours.
Process allocation:

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
No illustration available
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 28d: Polishing flecks


Data:
Definition: Restricted circular areas with a much smoother
surface than the surroundings.
Process allocation:

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 29: Polishing "fish" / "comet tails"


Data:
Definition: Depressions in a shape similar to that of a fish, caused
during the polishing process by a foreign body, a pore
or other pre-conditioning from earlier processes, such
as grinding.
Process allocation: 6, 9, 11, 13

Examples of permissible characteristic features:


Zone A: D < 0.3 mm, W < 2.5 mm, L < 5 mm
Max. 2 within a spacing of 400 mm
Zone B: D < 0.5 mm, W < 3 mm, L < 8 mm
Max. 4 within a spacing of 300 mm

No. 30: Polishing streaks


Data:
Definition: Very fine, localised raising of visible ribs, caused by
the polishing process (incorrect polishing paste and /
or disc was used).
Process allocation: 6, 9, 13, 16

Examples of permissible characteristic features:


Zone A: L < 60 mm, B < 0.5 mm,
Max. 6 within a spacing of 300 mm
Zone B: L < 80 mm, B < 3 mm,
Max. 10 within a spacing of 200 mm

No. 31: Pores


Data:
Definition: Small holes, visible with the naked eye, in the top
coating, which may penetrate to the base material in
places.
Process allocation: 2, 3, 6, 13, 15

Examples of permissible characteristic features:


Zone A: See Section 10.2
Zone B: See Section 10.2

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 32: Indications of seams / seam-welds


Data:
Definition: Identification:
Traces of longitudinal seams (extrusion press marks)
Traces of weld areas.
Description & effects:
Traces of (narrow) streaks, running in the direction in which
the part was formed, where the area is seen as lighter or
darker than the surrounding material, depending on lighting
No illustration available conditions. They can also occur in association with sink-marks
or step-marks. Indications of longitudinal seam / seam-welds
are caused by manufacturing processes and are unavoidable;
however, the level of their appearance can be influenced.

Process allocation: 4, 8

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 33: Scour marks


Data:
Definition: Flat, local roughing of the surface, generally seen as
differences in levels of sheen.
Process allocation: 6, 10, 13, 15

Examples of permissible characteristic features:


Zone A: Not acceptable
Zone B: Refer to MTP sample(s)

No. 34: Step marks (linear traces of rolling)


Data:
Definition: Stripes, running parallel to the direction of the
pressing / extrusion, over the length of the profile,
generally in the form of “steps“ , which are especially
visible after a coating process.
Process allocation: 4, 6, 8, 15

Examples of permissible characteristic features:


No illustration available
Zone A: Not acceptable if visible at > 800 mm.
Zone B: Not acceptable if visible at > 1200 mm.

No. 35: Striations


Data:
Definition: Liquation streaks with an electro-potentiostatic effect,
caused by pre-treatment for anodising and resulting
from liquation in the incoming material
Process allocation: 8, 11

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 36: Graininess


Data:
Definition: Slight graininess of a galvanised surface; comparable
with the "orange peel" appearance on painted surfaces
Process allocation: 6

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 37: Corrugations


Data:
Definition: Wave-like, parallel marks on the surface of the panel or profile,
at an angle to the direction of rolling or compression, which
can be seen in special observation positions (e.g., looking in
the rear-view mirror, reflection in a longitudinal direction at a
very shallow angle of observation).

Process allocation: 6, 8, 9, 11, 13, 16


Examples of permissible characteristic features:
Zone A: Not permitted when checked under the following conditions :
● component in its "installed" position
● artificial light-source 1.2 m over the component
● checked at 2.5 m ± 0.5 m from the component
● direction of observation is at 20°-45° to the longitudinal axis
of the vehicle with static observation

Zone B: Not permitted if visible at > 4 m


when evaluated as described for Zone A

No. 38a: Cloudiness/ fogging/ streaks


Data:
Definition: When polishing: local areas which are matt, dull, cloudy or
streaky, with diffuse transfer between different areas (process
allocation 9).
When painting: noticeable, partially light or dark areas within a
(metallic) paint finish with diffuse transfer from one area to the
next (process allocation 3).
Dull areas within the overall surface; with diffuse transfer from
one area to the next
Process allocation 6, 7)

Process allocation: 3, 6, 7, 9, 13
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 38b: Streaks caused by moisture / air


Data:
Definition: These occur during plastic injection moulding and are
caused by moisture in the plastic or air inclusions
during the injection moulding process.
Process allocation: 9, 12
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 39: Differences in coating thicknesses


Data:
Definition: These occur during galvanizing as a result of
inappropriate current density distribution (process
allocation 6) or in other processes because of different
particulate flows / flow angles or separation conditions.
Process allocation: 2, 3, 6
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 40: Sink marks


Data:
Definition: Visible dents in the surface, caused by elements on
the other side of the component, such as ribs, steps
and domes (process allocation 6).
Dents in the surface, caused by inappropriate
component geometry and / or shrinkage (process
allocation 12).
Process allocation: 6, 12, 13, 15
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 41: Converging flow marks


Data:
Definition: Visible scratch-like flow-marks on plastic parts where
flow fronts converge.
Process allocation: 6, 13, 15
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 42: Sucker marks


Data:
Definition: The result of contact between the surface and rubber
suckers. They are visible marks, caused by sucker
deposits when removing the part following the process.
Process allocation: 3, 6, 12, 15, 16
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 43: Seam welds


Data:
Definition: These occur at the convergence of two mass flows
after piercings and domes (converging seam welds).
Process allocation: 12, 13, 15
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
No illustration available Zone B: Refer to MTP sample(s)

No. 44: Moisture inclusions


Data:
Definition: Damp material, caused by incorrect preparation of the
material. Expanding moisture is deposited as streaks
or bubbles on the surface of the article.
Process allocation: 2, 5, 12, 13
Examples of permissible characteristic features:

No illustration available Zone A: Not acceptable


Zone B: Refer to MTP sample(s) Acceptable

No. 45: Holes


Data:
Definition: Holes in the surface coating, visible with the naked
eye, penetrating to the base material.
Process allocation: 6
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Refer to MTP sample(s)

No. 46: Alignment gap / offset


Data:
Definition: Alignment gap :
Caused by inaccurate alignment of veneers / a line is
visible.
Alignment offset :
Caused by inaccurate alignment of veneer / an offset
in structural symmetry
Process allocation: 13
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Acceptable

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 47: Patch marks


Data:
Definition: Caused by voids, holes and splits.
Process allocation: 13
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Acceptable

No. 48: Jagged knife edges


Data:
Definition: Damage caused by a knife when peeling / deburring
the component.
Process allocation: 13
Examples of permissible characteristic features:
Zone A: Not acceptable
Zone B: Refer to MTP sample(s)

No. 49: Differences in structure and texture


Data:
Definition: Uneven structure. Branches and bars not adequately
formed. This occurs in nature.
Process allocation: 13
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Acceptable

No. 50: Compressed folds


Data:
Definition: Visible lines; overlapping materials.
Process allocation: 13
Examples of permissible characteristic features:
Zone A: Refer to MTP sample(s)
Zone B: Acceptable

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

No. 51: Paint residues


Data:
Definition: Parts of the surface have not been removed by the
laser process.
Process allocation: 17
Examples of permissible characteristic features:
Zone A: Not acceptable
No illustration available Zone B: Refer to MTP sample(s)

No. 52: Burn marks


Data:
Definition: Thermal changes in the plastic substrate (changes in
colour).
Process allocation: 5, 17

Examples of permissible characteristic features:


Zone A: Refer to MTP sample(s)
No illustration available
Zone B: Refer to MTP sample(s)

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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16
Decorative Surface of
Attachment & Functional Parts to the Appendix to VDA Volume 16
Exterior and Interior of Automobiles 2nd revised edition, 2008

Imprint

The entire contents of these pages are protected by copyright.

Responsible for contents:

VDA QMC
Qualitäts Management Center
im Verband der Automobilindustrie
VDA QMC
An den Drei Hasen 31
D-61440 Oberursel
GERMANY

Phone: +49 (0)6171 / 9122-0


Fax: +49 (0)6171 / 9122-14
E-Mail: info@vda-qmc.de
Web: www.vda-qmc.de

In spite of great care mistakes can not be completely ruled out.


In the case of differing information please consider the printed VDA Volume 16 as correct.

Version 1.0

Source Legend:
1) Anodizing 7) Plasma process (evaporation, sputter, CVD, PVD) 13) Refined wood surfaces
2) Powder coating (EPS) 8) Over-moulding 14) Application technology (gluing insert foils, embossing decorative foils)
3) Wet painting 9) Polishing 15) Metal die-casting
4) Extrusion 10) Assembly / packaging / handling 16) Mechanical processing (grinding, polishing, deburring, drilling, milling, insertion, etc.)
5) Injection moulding 11) Incoming material 17) Laser lettering
6) Galvanizing 12) Plastic processing

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Attribute Gage R & R Effectiveness
Instructions:
1) The following spreadsheet is used to calculate an Attribute GR&R Effectiveness, in which up to
100 samples can be evaluated, using 2 or 3 operators.
2) In the Data Entry worksheet fill in the appropriate information in the Scoring Report section and
enter the type of Attributes you are evaluating in the Attribute Legend section. YOU MUST ENTER
THE INFORMATION IN THE ATTRIBUTE LEGEND SECTION OR THE SPREADSHEET
WILL NOT WORK. The attributes can be either alpha or numeric, e.g. Yes, No; pass, fail;
go, stop; or 1, 2. You must be consistent throughout the form and spell properly.
3) If you or an expert has selected samples to be evaluated and you know what attributes these
samples are, enter this information in the Attribute sample column. This will enable you to determine
how well each operator can evaluate a set of samples against a known standard. You do not
need to enter information in this column for the spreadsheet to work although you will
not be able to assess the operators against known standards.
4) You do not have to specify how many operators or the # of samples that you will be evaluating
during the test. Simply enter the data into the spreadsheet under the specific operator. Remember
the attributes must be spelled properly or the spreadsheet will not analyze the data correctly.
5) To print a copy of the report click on the Print Report icon.
6) To delete the data in the spreadsheet, click on the Delete Data icon.
7) To delete all and begin a new test, click on the Delete All icon
8) To see a Demo of the Attribute GR&R Effectiveness spreadsheet, click on the Demo icon.
Move around the spread sheet to see the data. When you are finished click the Delete All icon
to delete all data to begin entering your own data.

The 95% UCL and 95% LCL represent the 95% upper and lower confidence limits on the
binomial distribution. The Calculated Score is the basic computation reported on the report
page for % Appraiser and % Score vs Attribute. The 95% confidence interval represents
the range within which the true Calculated Score lies given the uncertainty associated with
limited sample sizes. As sample size increases (in this case, Total Inspected) the
confidence interval will get smaller and smaller which indicates more reliable estimates of
the true percentages. In the case of the Demo data, the true Calculated score for Operator 1
could be as low as 76.8% given that only 14 samples inspected, even though there was a 100%
Appraiser value calculated. Also, even though Operator 2 had a lower score, Operators 1 and 3
cannot be distinguished from Operator 2 because the calculated score of #2 (78.6%) lies within
the confidence limits for Operators 1 and 3.

With a worksheet limitation of 100 samples, at best a lower 95% limit of 96.4% can be calculated.
Thus, we would have to say that an inspector could be as bad as 96% efficient, even though he/she
missed no calls.

Sample Size 30 < Try out different combinations of number of samples and number of matches
# Matches 30 < to see the effects of sample size. In this case, a sample size of 30 with
95% UCL 100,0% < one non-match will yield a 17% confidence interval. In order to get reasonable
Calculated Score 100,0% < reliability in estimates of efficiency, large sample sizes will be required.
95% LCL 88,4%

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Data Entry

Attribute Gage R & R Effectiveness

SCORING REPORT
DATE: 04.01.2001
5
Attribute Legend (used in computations) NAME: Acme Employee
1 Pass PRODUCT: Widgets All operators

2 Fail BUSINESS: Earth Products agree within and All Operators


between each agree with
Other standard
Known Population Operator #1 Operator #2 Operator #3 Y/N Y/N
Sample # Attribute Try #1 Try #2 Try #1 Try #2 Try #1 Try #2 Agree Agree
1 Pass Pass Pass Pass Pass Pass Pass Y Y
2 Pass Pass Pass Pass Pass Pass Pass Y Y
3 Pass Pass Pass Pass Pass Pass Pass Y Y
4 Pass Pass Pass Pass Pass Fail Pass N N
5 Fail Fail Fail Fail Fail Pass Fail N N
6 Fail Pass Pass Pass Pass Pass Pass Y N
7 Pass Pass Pass Pass Pass Pass Pass Y Y
8 Pass Pass Pass Pass Pass Pass Pass Y Y
9 Fail Fail Fail Fail Fail Fail Fail Y Y
10 Pass Pass Pass Pass Pass Pass Pass Y Y
11 Pass Pass Pass Pass Pass Pass Pass Y Y
12 Pass Pass Pass Pass Pass Pass Pass Y Y
13 Pass Pass Pass Pass Pass Pass Pass Y Y
14 Pass Pass Pass Pass Pass Fail Pass N N
15 Fail Fail Fail Fail Fail Pass Fail N N
16 Pass Pass Pass Pass Pass Pass Pass Y Y
17 Pass Pass Pass Pass Pass Pass Pass Y Y
18 Pass Pass Pass Pass Pass Pass Pass Y Y
19 Fail Fail Fail Fail Fail Fail Fail Y Y
20 Pass Pass Pass Pass Pass Pass Pass Y Y
21 Pass Pass Pass Pass Pass Pass Pass Y Y
22 Pass Fail Fail Pass Pass Pass Pass N N
23 Pass Pass Pass Pass Pass Pass Pass Y Y
24 Pass Pass Pass Pass Pass Fail Pass N N
25 Fail Fail Fail Fail Fail Fail Fail Y Y
26 Pass Pass Pass Pass Pass Pass Pass Y Y
27 Pass Pass Pass Pass Pass Pass Pass Y Y
28 Pass Pass Pass Pass Pass Pass Pass Y Y
29 Fail Fail Fail Fail Fail Fail Fail Y Y
30 Pass Pass Pass Pass Pass Pass Pass Y Y
31
99
100
% APPRAISER SCORE(1) -> 100,00% 100,00% 83,33%
(2)
% SCORE VS. ATTRIBUTE -> 93,33% 96,67% 80,00%

SCREEN % EFFECTIVE SCORE(3) -> 80,00%


(4)
SCREEN % EFFECTIVE SCORE vs. ATTRIBUTE -> 76,67%

Note:
(1) Operator agrees with him/herself on both trials
(2) Operator agrees on both trials with the known standard
(3) All operators agreed within and between themselves
(4) All operators agreed within and between themselves AND agreed with the known standard
(5) Enter Pass/Fail, Good/Bad, Accept/Reject or other labels which indicate status of inspection

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Report
Attribute Gage R & R Effectiveness
SCORING REPORT
DATE: 04.01.2001
Attribute Legend NAME: Acme Employee
1 Pass PRODUCT: Widgets All operators
2 Fail BUSINESS: Earth Products agree within and All Operators
between each agree with
Other standard
Known Population Operator #1 Operator #2 Operator #3 Y/N Y/N
Sample # Attribute Try #1 Try #2 Try #1 Try #2 Try #1 Try #2 Agree Agree
1 Pass Pass Pass Pass Pass Pass Pass Y Y
2 Pass Pass Pass Pass Pass Pass Pass Y Y
3 Pass Pass Pass Pass Pass Pass Pass Y Y
4 Pass Pass Pass Pass Pass Fail Pass N N
5 Fail Fail Fail Fail Fail Pass Fail N N
6 Fail Pass Pass Pass Pass Pass Pass Y N
7 Pass Pass Pass Pass Pass Pass Pass Y Y
8 Pass Pass Pass Pass Pass Pass Pass Y Y
9 Fail Fail Fail Fail Fail Fail Fail Y Y
10 Pass Pass Pass Pass Pass Pass Pass Y Y
11 Pass Pass Pass Pass Pass Pass Pass Y Y
12 Pass Pass Pass Pass Pass Pass Pass Y Y
13 Pass Pass Pass Pass Pass Pass Pass Y Y
14 Pass Pass Pass Pass Pass Fail Pass N N
15 Fail Fail Fail Fail Fail Pass Fail N N
16 Pass Pass Pass Pass Pass Pass Pass Y Y
17 Pass Pass Pass Pass Pass Pass Pass Y Y
18 Pass Pass Pass Pass Pass Pass Pass Y Y
19 Fail Fail Fail Fail Fail Fail Fail Y Y
20 Pass Pass Pass Pass Pass Pass Pass Y Y
21 Pass Pass Pass Pass Pass Pass Pass Y Y
22 Pass Fail Fail Pass Pass Pass Pass N N
23 Pass Pass Pass Pass Pass Pass Pass Y Y
24 Pass Pass Pass Pass Pass Fail Pass N N
25 Fail Fail Fail Fail Fail Fail Fail Y Y
26 Pass Pass Pass Pass Pass Pass Pass Y Y
27 Pass Pass Pass Pass Pass Pass Pass Y Y
28 Pass Pass Pass Pass Pass Pass Pass Y Y
29 Fail Fail Fail Fail Fail Fail Fail Y Y
30 Pass Pass Pass Pass Pass Pass Pass Y Y
31 - - - - - - -
32 - - - - - - -
33 - - - - - - -
34 - - - - - - -
35 - - - - - - -
36 - - - - - - -
37 - - - - - - -
38 - - - - - - -
39 - - - - - - -
40 - - - - - - -
41 - - - - - - -
42 - - - - - - -
43 - - - - - - -
44 - - - - - - -
45 - - - - - - -
46 - - - - - - -
47 - - - - - - -
48 - - - - - - -
49 - - - - - - -
50 - - - - - - -
51 - - - - - - -
52 - - - - - - -
53 - - - - - - -
54 - - - - - - -
55 - - - - - - -
56 - - - - - - -
57 - - - - - - -
58 - - - - - - -
59 - - - - - - -
60 - - - - - - -
61 - - - - - - -
62 - - - - - - -
63 - - - - - - -
64 - - - - - - -
65 - - - - - - -
66 - - - - - - -
67 - - - - - - -
68 - - - - - - -
69 - - - - - - -
70 - - - - - - -
71 - - - - - - -
72 - - - - - - -
73 - - - - - - -
74 - - - - - - -
75 - - - - - - -
76 - - - - - - -
77 - - - - - - -
78 - - - - - - -
79 - - - - - - -
80 - - - - - - -
81 - - - - - - -
82 - - - - - - -
83 - - - - - - -
84 - - - - - - -
85 - - - - - - -
86 - - - - - - -
87 - - - - - - -
88 - - - - - - -
89 - - - - - - -
90 - - - - - - -
91 - - - - - - -
92 - - - - - - -
93 - - - - - - -
94 - - - - - - -
95 - - - - - - -
96 - - - - - - -
97 - - - - - - -
98 - - - - - - -
99 - - - - - - -
100 - - - - - - -

% APPRAISER SCORE(1) -> 100,00% 100,00% 83,33%


% SCORE VS. ATTRIBUTE(2) -> 93,33% 96,67% 80,00%

SCREEN % EFFECTIVE SCORE(3) -> 80,00%


SCREEN % EFFECTIVE SCORE vs. ATTRIBUTE(4) -> 76,67%

Note:
(1) Operator agrees with him/herself on both trials
(2) Operator agrees on both trials with the known standard
(3) All operators agreed within and between themselves
(4) All operators agreed within and between themselves AND agreed with the known standard
(5) Enter Pass/Fail, Good/Bad, Accept/Reject or other labels which indicate status of inspection Page 3 of 5
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Statistical Report - Attribute Gage R&R Study
DATE: 04.01.2001
NAME: Acme Employee
PRODUCT: Widgets
BUSINESS: Earth Products

% Appraiser1 %Score vs Attribute2


Source Operator #1 Operator #2 Operator #3 Operator #1 Operator #2 Operator #3
Total Inspected 30 30 30 30 30 30
# Matched 30 30 25 28 29 24
False Negative (operator rejected good product) 1 0 0
False Positive (operator accepted bad product) 1 1 1
Mixed 0 0 5
95% UCL 100,0% 100,0% 94,4% 99,2% 99,9% 92,3%
Calculated Score 100,0% 100,0% 83,3% 93,3% 96,7% 80,0%
95% LCL 88,4% 88,4% 65,3% 77,9% 82,8% 61,4%

Screen % Effective Score3 Screen % Effective Score vs Attribute4


Total Inspected 30 30
# in Agreement 24 23
95% UCL 92,3% 90,1%
Calculated Score 80,0% 76,7%
95% LCL 61,4% 57,7%

% Appraiser 95% UCL % Score vs Appraiser 95% UCL


Calculated Score Calculated Score
110,0% 95% LCL 110,0% 95% LCL

100,0% 100,0%
90,0% 90,0%
80,0% 80,0%
70,0% 70,0%
% Efficiency
% Efficiency

60,0% 60,0%
50,0% 50,0%
40,0% 40,0%
30,0% 30,0%
20,0% 20,0%
10,0% 10,0%
0,0% 0,0%
Operator #1 Operator #2 Operator #3 Operator #1 Operator #2 Operator #3

Notes
(1) Operator agrees with him/herself on both trials
(2) Operator agrees on both trials with the known standard
(3) All operators agreed within and between themselves
(4) All operators agreed within & between themselves AND agreed with the known standard

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Calculations
Known Population Operator #1 Operator #2 Operator #3 Y/N Y/N
Sample # Attribute Try #1 Try #2 Try #1 Try #2 Try #1 Try #2 Agree Agree
1 1 1 1 1 1 1 1 TRUE TRUE
2 1 1 1 1 1 1 1 TRUE TRUE
3 1 1 1 1 1 1 1 TRUE TRUE
4 1 1 1 1 1 2 1 FALSE FALSE
5 2 2 2 2 2 1 2 FALSE FALSE
6 2 1 1 1 1 1 1 TRUE FALSE
7 1 1 1 1 1 1 1 TRUE TRUE
8 1 1 1 1 1 1 1 TRUE TRUE
9 2 2 2 2 2 2 2 TRUE TRUE
10 1 1 1 1 1 1 1 TRUE TRUE
11 1 1 1 1 1 1 1 TRUE TRUE
12 1 1 1 1 1 1 1 TRUE TRUE
13 1 1 1 1 1 1 1 TRUE TRUE
14 1 1 1 1 1 2 1 FALSE FALSE
15 2 2 2 2 2 1 2 FALSE FALSE
16 1 1 1 1 1 1 1 TRUE TRUE
17 1 1 1 1 1 1 1 TRUE TRUE
18 1 1 1 1 1 1 1 TRUE TRUE
19 2 2 2 2 2 2 2 TRUE TRUE
20 1 1 1 1 1 1 1 TRUE TRUE
21 1 1 1 1 1 1 1 TRUE TRUE
22 1 2 2 1 1 1 1 FALSE FALSE
23 1 1 1 1 1 1 1 TRUE TRUE
24 1 1 1 1 1 2 1 FALSE FALSE
25 2 2 2 2 2 2 2 TRUE TRUE
26 1 1 1 1 1 1 1 TRUE TRUE
27 1 1 1 1 1 1 1 TRUE TRUE
28 1 1 1 1 1 1 1 TRUE TRUE
29 2 2 2 2 2 2 2 TRUE TRUE
30 1 1 1 1 1 1 1 TRUE TRUE
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
% Appraiser Score 100,00% 100,00% 83,33% Page 5 of 5
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