Transcript Supplier Contamination Prevention - Home

SUPPLIER CONTAMINATION PREVENTION
Guidelines and Awareness Training
SUPPLIER CONTAMINATION PREVENTION
Agenda
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Purpose
Contamination and Craters
Recommendations
Summary
SUPPLIER CONTAMINATION PREVENTION
Purpose
• Contamination continues to be an
issue at PPG
• Multiple occurrences related to raw
materials, containers or transport
• Awareness training is part of PPG’s
overall contamination prevention
strategy
SUPPLIER CONTAMINATION PREVENTION
What do we mean by contamination?
Particles from the air, containers
Dried pigment or resin
Fibers from clothing, mops, rags, boxes
Metal shavings, wood splinters
Craters Low surface tension contaminants
Maintenance materials
Personal care products
Contaminants in our raw materials
Silicone and non-silicone additives
Dirt
SUPPLIER CONTAMINATION PREVENTION
What do we mean by DIRT?
• Any particulate or fibres found in our paint –
excessive dirt can cause sanding issues at
our customer site.
SUPPLIER CONTAMINATION PREVENTION
What is a CRATER?
Craters are dish shape deformations in a paint surface.
Some are shallow dimples, others are deep that
penetrate to the substrate or layer below
SUPPLIER CONTAMINATION PREVENTION
Cost of Craters
Disruption of
an OEM
assembly line
Approximately
$10,000 per
minute!
SUPPLIER CONTAMINATION PREVENTION
Cost of Contamination
• Additional labor for sanding, repairs
and rework
• Car bodies scrapped - $3000 each
• Paint system at OEM dumped &
cleaned - $4000 + disposal costs
• Scrapped inventory at PPG
• Laboratory testing, site investigations
and supplier claims
SUPPLIER CONTAMINATION PREVENTION
BIGGEST Cost of Contamination
Loss of Customer
Confidence
Loss of business
to PPG
SUPPLIER CONTAMINATION PREVENTION
Solvent Tank Wagons - Sampling and Testing
• Sampling attachment used on
incoming solvent tank wagons
• Filter allows PPG to assess
amount of particles and fibers
• Gels can be an indicator of
crater causing contamination
• Failed testing will result in a
rejected tank wagon
SUPPLIER CONTAMINATION PREVENTION
Tank Wagons – Sampling and Testing
• 500 wagons are tested annually
at PPG Cleveland
• 7 wagons have been rejected in
2012 because of excessive
contamination
• Other PPG locations
experiencing tank wagon issues
as well
• Audits and corrective actions
implemented at suppliers
SUPPLIER CONTAMINATION PREVENTION
Tank Wagons - Requirements
Prior Contents
• Use dedicated tank wagons where possible
• If not dedicated, must have a system of
reviewing prior contents of each tank wagon
used for PPG Material
• Use PPG list of prohibited materials in review of
prior contents - contact PPG if there are ANY
questions!
SUPPLIER CONTAMINATION PREVENTION
Tank Wagons - PPG Requirements
Prior Contents Prohibited List
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Silicones
Fluorocarbons and fluorine based additives
Pigment dispersing agents
Release agents and adhesion promoters
Refrigerants
Waxes and cleaning compounds
Greases and oils
Epoxy resin, cationic epoxy and aqueous epoxy
Acrylic emulsions
Strong acids and bases
Slurries, dry powder and dispersions
SUPPLIER CONTAMINATION PREVENTION
Tank Wagons - PPG Requirements
Cleaning Methods
• Ensure correct cleaning methods
− Caustic clean (no detergent) + thorough rinsing
− External bottom valve and dome lid disassembled
and cleaned
− Inside inspection – visual and feel
• Procedure for pre-cleaning a new tank wagon
must be in place
− preliminary testing required before filling
SUPPLIER CONTAMINATION PREVENTION
Containers – Approval and Testing
Totes, Drums, Pails
• All containers types must be
pre-approved by PPG
• Tote cleaners are audited
annually
• Drum and pail manufacturers
are also audited
• Drums are sampled from
every new lot received and
tested for dirt
SUPPLIER CONTAMINATION PREVENTION
Maintenance Materials Controls
Maintenance List + Visual Aids
PPG’s controlled list is called MRL (Material Registration List)
• All maintenance materials at PPG are
crater tested
• Maintenance materials that FAIL are
eliminated where possible
• A system has been created with
stickers that is understood by all
employees
SUPPLIER CONTAMINATION PREVENTION
Maintenance Materials Controls
Use of stickers as a visual aid
SUPPLIER CONTAMINATION PREVENTION
Products that scare us!
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WD-40 widely used but causes craters
Rain X widely used but causes craters
Silicone based lubricants
Greases with low surface tension
components
• There are equivalent products
available to use in place of failed
products
SEE PPG’s
LIST!
SUPPLIER CONTAMINATION PREVENTION
Processing Equipment
Equipment Pre-Cleaning
‘de-bugging’
• Any equipment that is new must
be pre-cleaned – disassembled
and cleaned with solvent, then
tested
• Pre-cleaning should be done
after all repairs or replacements
SUPPLIER CONTAMINATION PREVENTION
Processing Equipment - Purchasing
Valves, gaskets, etc.
• Establish a silicone free
purchasing policy for valves
• Maintain a list of approved
equipment that can be
purchased
• Equipment still needs precleaning
Drum
valve
failed
testing!
SUPPLIER CONTAMINATION PREVENTION
Gaskets Used in Hoses/Totes
• Gaskets sampled and tested - failed
• Gasket supplier used silicone release agent
• Now have new gaskets
• Use “Talc” for release and will
• Have an orange stripe to signify “Talc release”
SUPPLIER CONTAMINATION PREVENTION
Silicone Handling
Visual Controls at PPG for
Silicone Materials
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Pink label
Pink skid
Quarantine area
Designated equipment
for weighing and
dispensing
SUPPLIER CONTAMINATION PREVENTION
Silicone Handling at PPG
“SILICONE ONLY”
tools
WASTE pails
for Silicone
Storage Bin
for designated
tools
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SUPPLIER CONTAMINATION PREVENTION
Gloves
Nitrile Gloves
• Gloves have caused false results
in crater testing
• Silicone is commonly used in the
glove manufacturing process –
release agent
• Need to specify silicone-free
gloves from distributor
SUPPLIER CONTAMINATION PREVENTION
Work Wear
Operators’ Clothing
• PPG garments have been tested
• Garment manufacturing and
cleaning process has been
audited and reviewed
—No silicone additives in detergents
—No silicone infused thread
SUPPLIER CONTAMINATION PREVENTION
Personal Care Products
Silicone
Free!
Hand Lotions
• Over 50 hand lotions were
tested for craters - 95% failed!
• Recommendation: provide
APPROVED hand lotion in
production and laboratory
areas
SUPPLIER CONTAMINATION PREVENTION
Personal Care Products
Critical in
certain
processes
Evaluate
risk at your
facility!
SUPPLIER CONTAMINATION PREVENTION
The Tale of Two Deodorants
The
Good
(passes)
24H
Deodorant
Invisible
Solid
The
Bad
(fails)
24H
Anti-Perspirant
& Deodorant
Stick
The
UGLY!
ATTENTION: Jim Blagg / QA Core, Bldg 4
SUPPLIER CONTAMINATION PREVENTION
Personal Hygiene
• Wash hands after meals –
some food ingredients cause
craters
• Change out heavily soiled
garments, shoes or gloves
• Wear gloves when directly
handling materials
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SUPPLIER CONTAMINATION PREVENTION
Housekeeping and Contamination Prevention
Key Areas
• Raw material containers & skids
SUPPLIER CONTAMINATION PREVENTION
Housekeeping and Contamination Prevention
Key Areas
• Processing equipment
• Blending vessels
• Transfer pumps
• Sampling cups
• Spill containment
SUPPLIER CONTAMINATION PREVENTION
Overall Housekeeping
• Decrease risk of contamination
• Decrease risk of errors
SUPPLIER CONTAMINATION PREVENTION
SUMMARY
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Contamination prevention critical for PPG
Guidelines and recommended procedures
 Bulk tank wagons – prior contents & cleaning
 Bulk tank wagons – sampling & testing
 Drums – tested, totes cleaners – audited
 Maintenance materials – listed and controlled
 Pre-cleaning – all new or repaired equipment
 Silicone handling – procedures and quarantine
 Work wear – tested and approved
SUPPLIER CONTAMINATION PREVENTION
SUMMARY
Personal care products
 Use only approved hand lotion
 Evaluate risk of personal care products
 Personal hygiene – washing hands
 Housekeeping is critical
 Cleaning procedures and visual controls
 Keeping lids closed
 Overall housekeeping
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SUPPLIER CONTAMINATION PREVENTION
Tools for Reducing Risk
Resources and Guidelines – Supplier Portal
https://buyat.ppg.com/suppliernetwork/frmSNWebPortal.asp
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PPG’s Maintenance Materials List (MRL)
Crater Pre-Cleaning Procedure
Silicone Valve Warning & Lube Free Letter
Bulk and Bulk Solvent Prior Contents Requirements
Change Notification Instructions and Form
SUPPLIER CONTAMINATION PREVENTION
Questions?
Comments?
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