1. Paint Plant. Data Driven Quality
Performance Improvement .
September 2014 – January 2016
QUALITYQUALITY

2. Plan- GLOBAL 8D. Structured
Approach using 8 Disciplines.
D1. Form the Team.
Cross Functional selected from Paint and Maintenance
departments
1.Facilitator P.Cunningham.
2.Champions S.Fitter. Yogi Krawetz. P.Segui
DIRT 8D Team . Pre Clean, Base Coat, Lacquer, Polish,
Maintenance personnel and Paint Team Leader

3. Plan- GLOBAL 8D. Structured
Approach using 8 Disciplines.
D2. Describing the Problem.
1.Variable Right First Time Performance on painted Bodies
viewed at Gateway 3 Buy Off. During September 2014
Averaging 70 % Failures which required Paint repairs.
2. Highest RFT Failure Mode on bodies was for dirt. Dirt count
from 300 to 700 pieces on all panels around the body.
3.Variable ability to support track requirement which is
between 8-10 bodies per day. Track stoppages waiting for
Bodies to be available after Paint Combi repairs. Body bank
for track was empty. The Body bank should have a minimum
of 2 and a Maximum of 10 ready to go on Pre Mount.
4. Various opinions of where Dirt originates from.

4. Plan – Implement Gateway 3 RFT
Measuring from Week 33 2014
2014 to 2015 Week 33 to Week 52 RFT
Comparisons
wk 45 2014.Unable to carry
out cleaning procedures
during October shutdown

5. Plan – Analyse RFT Failures.
2014 to 2015 Comparisons
Count
PercentPaint Plant. Gateway 3 Defects
Count 3 1
Percent 34.319.7 17.914.9 5.7 3.6 1.8
115
0.9 0.9 0.3
Cum % 34.354.0 71.986.992.596.1
66
97.998.899.7100.0
60 50 19 12 6 3
Other
Sealer
Dry
Spray.( Inside
and
Out)
ContactDam
age
LO
B
PaintDam
age
Runs
Dent
Craters
Dirt
350
300
250
200
150
100
50
0
100
80
60
40
20
0
Paint RFT Failures weeks 33 to 52 2014
Count
Percent
Paint Plant. Gateway 3 Defects
Count 2 2 1 1 0
Percent 41 17 12 7
39
6 5 3 2 2 2 1 1 0
Cum %
16
41 58 69 77 83 88 92 94 96 98
11
99 100100
7 6 5 3 2
Other
Sags
( d/leg)
Gun
Spills
Sealer
Dry
Spray. ( Inside
and
Out)
Contact Dam
age
LO
B
Splashes
Dent
Prep
M
arks
Runs
PaintDam
age
Dirt
100
80
60
40
20
0
100
80
60
40
20
0
Paint RFT Failures weeks 33 to 52 2015
Wk 33 to 52 2014 – 374 RFT Fails to Combi
Average 21 Bodies per week
requiring Combi repairs
Wk 33 to 52 2014 – 374 RFT Fails to Combi
Average 21 Bodies per week
requiring Combi repairs
Wk 33 to 52 2015 – 95 RFT Fails to Combi
Average 5 Bodies per week
requiring Combi repairs
Wk 33 to 52 2015 – 95 RFT Fails to Combi
Average 5 Bodies per week
requiring Combi repairs

6. Do- GLOBAL 8D. Structured
Approach using 8 Disciplines.
D3. Containment.
Protecting the Customer. Our Customers are Gateway 3 Buy Off and
Pre Mount on the Track.
These are the Containment Actions that were implemented.
1.BIW – Green Room. A more thorough vacuum of bodies for iron
filings from BIW rework.
2.Post Scuff Booth blowing off of dust. Tak off Bodies inside and
out. Water Wash and Tak off bodies before going into Pre Clean
Room.
3.Pre Clean. Clean with White Spirit ,tak off and heat with infa red
lamp.
4.Base Coat .Final Tak, Base and Dry.
5.Lacquer booth . Dry , Tak and Lacquer.

7. Do- GLOBAL 8D Structured
Approach using 8 Diciplines
D4. Root Cause Analysis. Team Based Input.
Cause and Effects Dirt in Painted Parts. 17 High Ranked Potential Causes

8. Do.GLOBAL 8D.Structured
Approach using 8 Diciplines.
D4. Root Cause Analysis.
Areas of focus resulting from 17 Ranked High Potential Causes.
1.The condition of the Paint Facility through wear and tear
particularly through the aggressive nature of Lacquer.
2.Little or no Booth Cleaning Programme. No regular frequencies.
3.A review of Critical to Quality Maintenance. Inclusive of Base and
Lacquer fans that incur high build ups of paint material that lead to
fans being out of balance. This increases vibration of the booths
which leads to increases of dirt onto the vehicles from the ceilings
of Base Coat and Lacquer Booths.
4.Frequency and level of cleaning and re sealing of oven floor.
This is not structured or regular.
5. Lack of early warning “Trigger Points “ for Dirt levels that
could be increasing at Critical stages of Processing.

9. Do.GLOBAL 8D.Structured
Approach using 8 Diciplines.
D5.Permanent Corrective Actions.
1. Facility Deep Clean. Develop a working standard for elements that
were failing or broken. The initial 30% was carried out in September
2014. The remaining 70% carried out at Shutdowns in October,
Christmas and Easter 2015. Lessons learnt put into Maintenance
PPM’s schedules.
2. Development and Implementation of Pre Clean, Base Coat and
Lacquer booth Daily and Weekly Cleaning program.
3. Oven Maintenance . Weekly and Fortnightly vacuum and Floor
Resealing
4. Fortnightly Base Coat and Lacquer Fans cleaning. Continuous
rotation. Of fan cleaning.
5. Oven Floor repairs and re sealing around floor filters where floor
breaking away and increasing dirt levels.
6. Closed Door Policy introduced for all booth areas from BIW Combi
through paint plant to end of Oven. Doors are kept closed.
7. Better organisation of overalls and consumables for Spraying.
8. Clean up of Blowers and improved rotation for cleaning when fouled
with Base Coat and Lacquer paint.

10. Check.GLOBAL 8D.Structured
Approach using 8 Diciplines.
D6. Validation.
“ Being Proactive as opposed to Reactive”
1.Pre Start Checks on Critical to Quality Parameters. For Pre Clean
Room , Base Coat and Lacquer Booths.
2. Statistical Process Control chart ( SPC ) monitoring Twice Daily
After Lacquer v Post Oven Dirt counts on Bodies. Monitoring
Individual and Range . Identifying Trends.
3. Statistical Process Control chart ( SPC ) Chart monitoring Body
to Body dirt counts on Bodies at Gateway 3 Buy Off. Monitoring
Average and Range. Identifying Trends.
4. Use of Thermal Imaging camera inside oven weekly, to monitor
temperature levels and also to identify heat leaks.( cracks in oven
floor.)

11. Check.GLOBAL 8D.Structured
Approach using 8 Diciplines.
D6. Validation – Trigger Points.
Pre Start Checks. 07.00 Daily.
Pre Clean, Base Coat and Lacquer booths.
1.Walk and Audit .
2.Adhering to established Care Point
Standards
SPC.At Lacquer v Post Oven. Twice Daily. 2
Pts rising = STOP and validate Pre Clean to
Oven
SPC Body to Body Gateway 3. 4 Points rising
= STOP and Validate Pre Clean to Oven

12. Act..GLOBAL 8D.Structured
Approach using 8 Diciplines.
D7. Prevention. Using Data to make informed decision making.
“Being Proactive rather than Reactive”
1.Pre Start Checks on Critical to Quality Parameters. Stop / Fix
Approach. Pre Clean Room, Base Coat and Lacquer booths.
2.Statistical Process Control . (SPC) Dirt After Lacquer v Post Oven.
After Lacquer 50 pieces + 10 pieces. After Oven 150 pieces + 20 Max /
2 Points rising is a Stop / Validate Processes and Facility from Pre
Clean ,Base Coat, Lacquer and Oven.
3.Statistical Process Control. ( SPC ) Dirt Body to Body 150 pieces +
50 pieces / 4 Points rising or an extreme High Count is a Stop /
Validate Processes from Pre Clean, Base Coat ,Lacquer and Oven.
“Right Routines for the Right Reasons at the Right Time- Every Time!!!”
“We do not knowingly – Accept, create or pass on Defects.”

13. A Picture Says a Thousand Words.
Well Done the Team !!!!!!
D8.Congratulate the Team.