Vdocuments - MX - Vda Volume 16 English

8/10/2019 VDA Volume 16 English
Verband der
Automobilindustrie
Quality Management
in the Automobile Industry
Decorative surfaces of external fittings
16
and functional
externals parts in the internal and
of automobiles
Evaluation conditions
Definitions of characteristics and dealing with defects
Acceptance criteria
2nd. revised edition, 2008
http://slidepdf.com/reader/full/vda-volume-16-english 1/20
Decorative surfaces of external fittings

and functional parts in the internal and
external areas of automobiles
Evaluation conditions
Definitions of characteristics and dealing with defects
Acceptance criteria
ISSN 0943-9412
Copyright 2008 by
Verband der Automobilindustrie e.V. (VDA)

Quality Management Centre (QMC)
2nd revised edition 2008
61440 Oberursel, An den Drei Hasen 31
Germany
Verband der Automobilindustrie e.V. (VDA) Overall production

Henrich Druck + Medien GmbH
60528 Frankfurt am Main, Schwanheimer Straße 110
Germany
Printed on chlorine-free bleached paper
Contents Page 8 Evaluation method 27
0 Preamble 7 9 Miscellaneous 27
1 Objective / purpose 8 10 Appendix data 28

10.1 Table showing examples of acceptable characteristics 28
2 Area of application 8 10.2 Table showing examples of quantifiable characteristics,
based on Table 10.1 32
3 Validity 8 10.2.1 Example of classification by size and permitted frequency 32
10.2.2 Example of classification by minimum distance between
4 Evaluation zones 9 individual defects 32
5 Evaluation conditions 11 10.3 Table showing examples of practice-related observation

periods 33
5.1 Position 11
10.4 Example of a ppm calculation, taking account of items
5.2 Lighting conditions 11
which slip through 34
5.2.1 Brightness and colour temperature (exterior/interior) 11
10.5 Pictures to aid discussion of characteristics 33
5.2.2 Lighting angle 12
10.6 Attributive gauge R & R effectiveness 33
5.2.3 Orientation of the light source 12
5.3 Observation distance 13 11 Bibliography 35
5.4 Observation period: 13
5.5
5.5.1 Target
ppm andagreements
degree of validity 13
13
5.5.2. Quality position 14
5.5.3 Determining the quality position 15
5.5.4 Special ppm agreements 15
5.6 Ensuring the comparability of inspectors and inspection
requirements – aligniing the evaluation standard 15
5.7 Handling samples from a process at maximum tolerance
limits (MTP samples) and limit samples 18
6 Defining characteristics / addressing defects 21
7 Acceptance criteria 27
7.1 Acceptable characteristics 27
7.2 Quantifiable characteristics 27
7.2.1 Classification 27
7.2.2 Permitted density / frequency 27
5 6
0 Preamble 1 Objective / purpose
It is expressly emphasized that this VDA volume does not represent a This VDA volume is intended to serve as an initial basis for bilateral
new surface specification for parts with surfaces which are judged by negotiations between OEM and supplier, as well as between customer and
subjective evaluation. supplier throughoutcharacteristics
for the subjective the entire supply chain whensurfaces.
of decorative agreeing The
a specification
results of
This document must instead be regarded as a communication paper, such negotiations must then be recorded in individual contracts.
to be used as a support in the essential exchange of views between
customer and supplier, within the multi-lateral relationships in the It also serves to provide a clear and unambiguous description of
various automotive supply chains, with regard to the features of the decorative product surfaces (so-called “subjective surfaces”) and to specify
characteristics to be defined for the parts and process portfolio uniform test & inspection conditions, in order to prevent process problems
under consideration. for customers and suppliers because of imprecise or incomplete means of
measurement.
For those involved in production processes this VDA volume serves as a

training aid, to ensure that processes are applied in accordance with
agreed references.
To avoid the extra costs and quality problems which might arise from a
surface specification delayed until after SOP, the characteristics which are
technically achievable must be presented as early as possible in the
manufacturing feasibility analysis, as part of the project management
process. The requirements should then be laid down in agreement with the
customer, within the framework of advanced quality planning.
2 Area of application
This VDA volume applies to decorative surfaces of external fittings

and functional parts in the internal and external areas of automobiles.
The area of application is defined as the visible area of the vehicle which is
seen, whether standing or sitting, in the normal use of a vehicle.
3 Validity
The following types of products are primarily affected :

• Decorative strips, such as strips on handles, shaft coverings,
frames, crash-bars and side-protection bars, radiator grills and
decorative grids
• Panels (including mirrors)
• Covers in general
7 8
• Actuator elements, such as knobs, buttons, levers, switches, door- The following table sets out a possible method of zoning for various
handles, air inlet nozzles components in terms of the significance or weighting of the defect.
• Roof bars
• Luggage carriers (roof and tailgate systems
•
Emblems, lettering and plates ZONE DEFINITION ALLOCATION
• Mirror covers
• Fuel filler flaps A Surfaces in the immediate line of Exterior :
• Wood trim sight The vehicle above the observer's waist
line, extended if appropriate to describe
a specific zone
Consideration is also given to parts and surface-related items. The
material-specific characteristics of visible surfaces are dealt with in this Interior :
All parts in the direct line of sight of the
VDA volume only where they do not exclude or contradict the standards
persons in the vehicle
typically employed in the automobile sector.
B Surfaces not in the direct line of Exterior :
This VDA volume deals with the following manufacturing processes used sight, or not seen in their normal The vehicle below the observer's waist
to produce different surface finishes: position. line, down to the level of the bumpers
Observation sector < 45° and any functional elements (open flaps,
• Anodizing doors, etc.)
• Powder coating (EPS) Interior :
• Wet painting All surfaces which are not immediately
• Extrusion observable
• Plastic injection moulding

Optional: Surfaces which are concealed Surface has no relevance
• Galvanizing
• Plasma procedures (evaporation, sputtering, CVD, PVD) C following assembly
• Application techniques (adhesive/stamped decorative foils) Optional: Surfaces which have no
• Metal gravity die-casting D significance in terms of surface
coating but where the function
• Mechanical processing (e.g., grinding, polishing, deburring, drilling,
prohibits certain surface
milling, jointing) characteristics
• Laser lettering
No consideration is given in this VDA volume to any aspects of the colour Where concealed surfaces are concerned, the basic requirement is that
assessment or colour metrology of painted external parts. For these the functionality must not be affected.
reader is referred to existing regulations issued by OEMs and various
associations, as well as to international standards.
4 Evaluation zones
The types of evaluation zones must be specified in the component drawing

and/or the data model.
9 10
10.2 Table of example of quantifiable characteristics to Table 10.1
No. Type of Process Zone A Zone B
characteristic allocation
*) 10.2.1 Examples of classification by size and permitted frequency
46a Alignment gap 13 Limit sample Acceptable Maximum permitted total number of characteristics for a single reference
46b Alignment offset 13 Limit sample Acceptable
surface :
47 Patch marks 13 Limit sample Acceptable

Size Limits Frequency in Frequency in
48 Jagged knife 13 Zone A Zone B
Not acceptable Limit sample
edges
49 Diff erences in 13
Large > 0.5 mm to 0.8 mm 1 2
structure and Limit sample Acceptable
Medium 0.3 mm to < 0.5 mm 2 4
texture
Small < 0.3 mm 4 No restriction
50 Compressed folds 13 Limit sample Acceptable
51 Paint residues 17 Not acceptable Limit sample
52 Burn marks 5, 17 Limit sample Limit sample

10.2.2 Example of classification by minimum distance between
individual defects
*) Process allocation Characteristics extending no more than 0.4 mm in any direction are not
evaluated. Accumulations of more than 2 defects per 25 cm² are not
• 1) Anodizing permitted.
• 2) Powder coating (EPS)
• 3) Wet painting In Zone A two defects are permitted, provided they extend no more than
• 4) Extrusion 0.5 mm and they are more than 200 mm apart.
• 5) Injection moulding In Zone B two defects are permitted, provided they extend no more than
• 6) Galvanizing 0.75 mm and they are more than 100 mm apart.
• 7) Plasma process (evaporation, sputter, CVD, PVD)
If the product under examination is smaller than an enclosed circle of
• 8) Over-moulding
200 mm the following restriction applies :
• 9) Polishing
• 10) Assembly / packaging / handling Zone A:
• 11) Incoming material • max. 2 defects extending no more than 0.5 mm in any direction, for
• 12) Plastic processing surface areas up to 25 mm²
• 13) Refined wood surfaces • max. 3 defects extending no more than 0.5 mm in any direction, for
• 14) Application technology surface areas up to 25 mm²
(gluing insert foils, embossing decorative foils)
• 15) Metal die-casting Zone B:
• 16) Mechanical processing • max. 2 defects extending no more than 0.7 mm in any direction, for
(grinding, polishing, deburring, drilling, milling, insertion, etc.) surface areas up to 25 mm²
• 17) Laser lettering • max. 3 defects extending no more than 0.7 mm in any direction, for
surface areas up to 25 mm²
31 32
10.3 Table of examples of practice-related observation periods
Logos (small) 5 sec. Quantity inspected (100%of batch)

GWS panels 10 sec.
Front panels 15 sec.
Production
Gear clips 10 sec.
Chrome rings 5 sec.
Filler pieces 5 sec. 100%final inspection
Percentage OK
Exterior mirrors 20 to 30 sec., depending on complexity NOK
(delivery batch)
Trim strips 15 sec.
The following must be borne in mind when carrying out checks in full Unavoidable percentage of items slipping through the net in the
(delivery) batch. : PD = 0.003 – the equivalent of 0.3%
production :
Packing
It is not possible to distinguish between defective and
defect-free parts and defective parts slip through
•
Always examine the part in its installed position Example
• Prevent any reflection from the part Quantity inspected : 10 000 parts
Percentage found to be OK: 80%
• The aim is not to seek defective characteristics. Only those Quantity shipped : 8 000 parts
Ship off
characteristics recognized as outside the specified limits and MTP Unavoidable defective parts in delivery batch : 24 parts (3000 ppm)
samples are to be evaluated as defective.
10.5 Pictures to aid discussion of characteristics

10.4 Example of a ppm calculation, taking account of items
which slip through
See enclosed CD-ROM.
When dealing with the question of items which "slip through the net"
and the percentages involved (see Section 5.5.2) discussion will
always arise in practice. Because of this, an example is provided here
10.6 Attributive gauge R & R effectiveness
to explain the minimum percentage levels involved. This gives
concrete figures in illustrating the possible (unavoidable) percentage
The enclosed CD-ROM contains an executable EXCEL file with a
of defective parts in a delivery batch. demonstration program, to carry out an attributive check of this kind,
covering the comparability of inspectors and inspection checks in
The illustration takes a practical example, with figures, to show what accordance with Section 5.6 where parts with surfaces are judged on
part-quantities of a production batch or delivery batch in calculating subjective terms.
the associated ppm figures.
33 34
11 Bibliography Quality management in the automobile industry
The following research papers and reports should be taken into account The current position regarding VDA publications covering quality
when drawing up a specification. These contain references to other management in the automobile industry (QAI) is shown in the Internet
literature. under http://www.vda-qmc.de.
• Heinz Schmidke : "The ergonomics manual" (chapter dealing with You may also order via this home page.
workloads and stresses). Section 3.5 : "Problems with Wakefulness“.
• Prof. Dr. med. E. Grandjean : Physiological work-place layouts.

Section 9.3 : "Long-term attentiveness".
• Dr. phil. Martin Schütte : "Visual quality checking and mental stresses".
• DIN EN ISO 8785 : "Surface imperfections".
• KU-Marketing, Europa/VAT, Bayer AG, Leverkusen : "Injection

moulding – defects, causes and solutions".
• IWK RWTH Aachen : "Characteristics of aluminium extruded profiles".

In-house publication, 2001.
Available from :
• DGM : "Lists of defects in extrusion presses" (AK Leichtmetall).
Verband der Automobilindustrie e.V. (VDA)
Quality Management Centre (QMC)
• Working committee for metal castings at the FH Aalen : "List of defects
61440 Oberursel, An den Drei Hasen 31
in zinc pressure die castings", ISBN 3-932291-12-3.
Germany
Tel. :+49 (0) 6171 91 22-0. Fax : +49 (0) 6171 91 22-14
E-mail : info@vda-qmc.de, Internet: www.vda-qmc.de
Printed forms available from :
HENRICH DRUCK + MEDIEN GMBH

Schwanheimer Straße 110, 60528 Frankfurt am Main
Germany
Tel. : +49 (0) 69 9 67 777-158. Fax : +49 (0) 69 67 77-111

E-mail : dschwarz@henrich.de, Internet: www.henrich.de
35 36

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8/10/2019 VDA Volume 16 English

2nd. revised edition, 2008

Decorative surfaces of external fittings

Verband der Automobilindustrie e.V. (VDA)

Verband der Automobilindustrie e.V. (VDA) Overall production

Printed on chlorine-free bleached paper

Contents Page 8 Evaluation method 27

1 Objective / purpose 8 10 Appendix data 28

5 Evaluation conditions 11 10.3 Table showing examples of practice-related observation

6 Defining characteristics / addressing defects 21

0 Preamble 1 Objective / purpose

For those involved in production processes this VDA volume serves as a

This VDA volume applies to decorative surfaces of external fittings

The following types of products are primarily affected :

• Plastic injection moulding

The types of evaluation zones must be specified in the component drawing

47 Patch marks 13 Limit sample Acceptable

52 Burn marks 5, 17 Limit sample Limit sample

Logos (small) 5 sec. Quantity inspected (100%of batch)

samples are to be evaluated as defective.

10.5 Pictures to aid discussion of characteristics

• Prof. Dr. med. E. Grandjean : Physiological work-place layouts.

• DIN EN ISO 8785 : "Surface imperfections".

• KU-Marketing, Europa/VAT, Bayer AG, Leverkusen : "Injection

• IWK RWTH Aachen : "Characteristics of aluminium extruded profiles".

Printed forms available from :

HENRICH DRUCK + MEDIEN GMBH

Tel. : +49 (0) 69 9 67 777-158. Fax : +49 (0) 69 67 77-111

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