DESIGN MATIRX - GENERIC PAINT EXAMPLE

Product Code / Description : xxR-yyyy Basecoat Paint Project # :00001

Potential Causes
Prelimnary Special Characteristics

CATEGORY/CHARACTERISTICS

ROBUST THRESHOLD RANGE

FAILURE

UNITS
Formula Ingredients
Resin A under 40% Binder Solids
over 50% "
Resin B under 25% Binder Solids
over 35% "
Crosslinker under 20% Binder Solids
over 30% "
SC Rheology Control Additive under 0.50% Total Solids
over 2.50% "
Colour Dispersion - B under 1.00% Total Solids
over 2.00% "
Solvent - D under 5% Formula Weight
over 15% "
Alcohol Solvent under 2% Formula Weight
over 4% "
Ingredient Characteristics
Resin - A Viscosity under 30%
over 40%
Crosslinker-Imino (-NH) % under 1%
over 10%
Product Characteristics
SC Viscosity under 30 sec
over 40 sec
SC % NV Solids under 57%
over 61%
Resistivity under 0.01 megaohms
over 0.15 "
Process Constraints
Batch Mixing Temperature under 70 deg deg F
over 110 deg "
Conditions for Use
 Flash Time before Clear under 1 minutes
over 3 "
SC Final Bake Temperature under 250 deg deg F
over 275 deg "

NEGATIVE IMPACT ON CUSTOMER EXPECTATIONS :- HIGH = 3 ; MEDIUM = 2 ; LOW = 1 ; NONE = 0


Good Gloss/Image/Peel
No Telegraphing
APPEARANCE
No Pin-holing
3 1
3 1
1 1
1 1
1 2
1 2
1 1
1 1
1 1
2 1
3 1
2 1
1 1
1 1
3 2
2 1
1 1
1 1
2 2
1 1
1 1
1 1
2 1
1 1
1 1
2 1
No Mudcracking
Dirt/Seed free
1 1
1 1
3 1
1 1
3 1
1 1
3 1
1 1
1 1
1 1
2 2
1 1
1 1
1 1
1 1
1 1
1 1
1 1
1 1
1 1
1 2
1 1
1 0
1 0
1 1
1 1
Good Colour Match
Crater free
1 1
1 1
1 1
2 1
1 2
1 1
1 1
1 1
2 1
1 1
1 2
1 1
1 1
1 1
1 2
1 1
1 1
3 2
1 2
1 1
1 1
1 1
0 2
0 3
2 2
2 2
Function - Desired Attributes ( Potential Failure Modes )
Good FMVSS ( Windshield Acpt)
Good De-amination Resistance
Good Accelerated Durability
Workable Visc/Atomization
Good Crack Resistance
Good Florida Durability
Good Repair Adhesion
Good Chip Resistance
Good Sag Resistance
PROCESSABILITY
PERFORMANCE
0 2 3 2 1 1 1 1 2 1
0 2 2 1 2 1 1 1 2 1
1 1 2 3 1 1 2 2 1 1
1 2 2 2 1 1 1 2 1 1
1 2 2 3 1 2 2 2 1 1
1 2 2 2 1 3 1 2 1 1
0 1 1 1 1 1 1 1 3 2
1 1 1 1 1 1 1 1 2 1
3 2 1 2 1 1 2 2 1 1
1 1 1 3 1 1 1 1 1 1
0 1 1 1 1 1 1 1 1 2
1 1 1 1 1 1 1 1 3 2
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
0 1 1 1 1 1 1 1 1 2
1 1 1 1 1 1 1 1 1 3
0 1 2 2 2 2 2 2 1 1
1 1 2 3 3 2 2 3 1 1
2 1 1 1 1 1 1 1 3 3
3 1 1 1 1 1 1 1 2 3
1 1 1 1 1 1 1 1 2 2
1 1 1 1 1 1 1 1 2 2
0 0 0 0 0 0 0 0 1 3
0 0 0 0 0 0 0 0 1 3
2 1 1 1 1 1 1 1 1 1
3 2 2 1 2 1 1 2 1 1
 3 1 3 2 1 1 2 1 1 1 1 1 1 1 3 0
2 1 2 1 1 1 3 1 1 1 1 1 1 1 2 0
2 1 1 1 0 0 3 3 3 3 2 2 3 2 1 0
3 1 1 1 1 1 3 2 2 3 3 2 3 3 1 0

M = 2 ; LOW = 1 ; NONE = 0
Failure Modes )

Good Repair Processability

Good Circulation Stability

Low/Acceptable Odour
Good Hiding Latitude

Low/Acceptable VOC
Good Shelf Stability

ENVIRONMENTAL

HAPS Complaint
Stable Rheology

No Edge Pull

1 2 2 1 0 3 1 1 1
1 2 2 1 0 2 1 1 1
1 1 1 1 0 2 1 1 1
2 2 2 1 0 3 1 1 1
1 2 2 1 0 2 1 2 2
1 3 1 1 0 2 1 3 1
2 3 3 2 1 3 1 1 1
1 2 2 2 1 3 1 1 1
1 1 1 1 3 2 1 1 1
1 1 1 1 1 2 1 1 1
1 1 2 2 0 2 1 1 1
1 2 2 3 0 1 3 2 3
3 3 2 1 1 2 1 1 1
1 1 1 1 1 1 2 2 3

2 2 2 1 1 1 1 0 1
2 1 3 1 1 1 1 0 1
1 1 1 1 0 2 0 0 0
1 1 1 1 0 1 1 1 1

2 3 2 3 1 1 1 0 1
1 3 1 1 1 1 1 0 1
2 2 2 2 1 3 3 1 1
2 2 2 2 1 3 1 1 1
1 1 1 1 0 1 1 1 1
1 1 1 1 0 1 1 1 1

3 2 3 1 1 1 1 0 1
3 1 3 1 1 1 1 1 1
0 0 0 2 1 1 1 1 0
0 0 0 1 1 1 2 1 0
0 0 0 1 1 3 1 1 1
0 0 0 1 1 3 2 3 1
Bulk Material Requirement Checklist :-
Required / Primary Responsibility
Target Date
Customer Supplier
Product Design and Development Verification
Design Matrix
Design FMEA
Special Product Characteristics
Design Records
Prototype Control Plan
Appearance Approval Report
Master Sample
Test Results
Dimensional Results
Checking Aids
Engineering Approval.
Process Design and Development Verification
Process Flow Diagrams
Process FMEA
Special Process Characteristics
Pre-launch Control Plan
Production Control Plan
Measurement System Studies
Interim Approval
Product and Process Validation
Initial Process Studies
Part Submission Warrant
Elements to be completed as needed
Customer Plant Connection
Change Documentation
Subcontractor Considerations

Plan agreed by : Name Company / Title / Date :

Comments
/ Approved
Conditions by/Date