Issue link: http://www.e-digitaleditions.com/i/653106
Certainly this scenario is the exception and not the rule. In general, successful metal finishing professional are compe- tent and know their processing limita- tions. These are the companies that grow and truly become an extension of the companies that they service. Our industry has made several attempts at grading or qualifying custom coaters' professionalism by attempting to create supplier or organizational certification programs for competent metal finishing companies. In some cases, this approach has been successful; in some cases, it has only resulted in documented incompe- tence. Companies like Harley Davidson, Hass Automation, International Game Technology (IGT), and others have taken it upon themselves to mandate compliance by the development of a quality system that begins with a com- prehensive finishing specification that is designed to qualify suppliers and finish- ing materials to meet their individual finishing requirements. Companies like these have invested in the quality of their supplier base not because they want to, but because they have to. They cannot afford to let suppliers experi- ment with process and material changes without knowing what the end result will be in terms of quality and the expected service life of the finish. By having control over qualified materials and quality applicators, they are guaran- teed to get the finish that they are pay- ing for. Why leave quality to chance? The basis of a good quality management system is to simply: Say what you do, do what you say, and be prepared to prove it with documentation! Rules of engagement At a minimum, custom coaters should have basic policies that will outline the common approach to any project. By integrating the quality management system with the policies of the company, every employee can become an integral part of the customer service function. Owners and managers should strive to eliminate departments and integrate the quality management system into every part of the company. By develop- ing a systematic method of communi- cation with each customer and each part or project, you will find that new and existing customers will become confident in the professionalism of the organization as a whole. The following is a list of basic topics to address with each customer as a starting point in your working relationship. Pragmatic rules (suggestions) of engagement Guidelines for outsourcing powder finish- ing to custom coating companies Purpose: This listing shall serve as a guideline of the general responsibilities for outsourcing the services of powder coat finishing of fabricated products. This guideline is created for general metal decorative metal weldments and components. Specific functional appli- cations may require more detailed pro- cessing procedures and specialized pow- der material(s) that may require testing and approvals as deemed necessary on a project by project basis. Quotation: The quotation document shall be provided by the custom coater and will clearly identify the detailed processes and materials that will be applied to the customer's product. The document will accurately define the exact cost for the services rendered. First article approval: First article sam- ples and approvals are highly recom- mended prior to production processing. Samples shall be provided upon request by the customer for formal approval prior to production processing. Cus- tomer shall provide written proof of acceptance for color, gloss, texture, masking, or other requirements as stat- ed in the quotation document. Production part approval process (PPAP): Upon receipt of the formal quotation outlining the tasks and processes to be performed and after receipt of the first article(s) submitted for approval, a short production run of customer supplied parts should be processed, inspected, packaged, and delivered for final approval by the cus- tomer. Product traceability: Customer's product shall be identified and traced by the management system during the entire time that products are in the pos- session of the finisher. Labels shall be applied to identify purchase orders, work orders, and job disposition for each pallet or container of customer supplied product. Basis of acceptance: Basis of accep- tance of the powder coating finish for all components will be in accordance with the customer's finishing specification, purchase order requirements, the quo- tation documentation, and/or any addi- tional quality accept/reject criteria as defined and agreed upon in writing between the customer and the powder coating contractor. Specialized testing may be required to prequalify the select- ed powder coating material on specific substrates for the intended use. Unless otherwise required in writing, the cus- tomer is responsible for the cost and documentation required to qualify the total finishing system for the intended use by a third party laboratory. Powder material(s): The finished powder coating material color, texture, gloss, and chemistry shall be in the color specified in the contract (quotation and customer's purchase order documents). Color match to any standard shall be determined by signed first article approvals with a copy of the signed con- trol standard to be given to the cus- tomer and a copy to be held by the fin- ishing application contractor. Supplier control standards of batch manufactur- ing are also recommended for projects that require color control certification. Powder coating chemistry: The pow- der coating chemistry shall be selected by first article approval process and for- mal testing, preferably by the customer, for the intended use and in accordance with the coating contractor's formal quality management system or as speci- fied by the customer to the contractor by product name, number, chemistry, and supplier as listed on the purchase order from the customer. Typically, the responsibility for the selection of the powder for the intended use rests with the customer. Preproduction testing is always advisable. 26 POWDER COATING, March 2016