Manufacturing and Cosmetic Inspection Specification

Transcription

1 Document Reference: MISB-MACIS-Rev (1) Page 1 of 13 Manufacturing and Cosmetic Inspection Specification Revision Change History Rev No. Effective Date Affected Page Change Descriptions Prepared by Reviewed by Approved by 0 01 Jun 2009 All Initial Release KL Lee SH Ang Daniel Ong 1 01 Oct 2009 All Format update and add front page for Revision change history KL Lee SH Ang Daniel Ong

2 Document Reference: MISB-MACIS-Rev (1) Page 2 of Purpose To define the manufacturing standards & cosmetic inspection used within Mace Instrumentation in the absence of and with reference to customers own manufacturing requirements & cosmetic specifications. 2.0 Inspection Requirements 2.1 General Cosmetic inspection shall use the Time and Distance (T & D) inspection specification described below and shall rely on the judgment of trained inspectors and operators. The cosmetic Reference Standard defined in this specification is to be used for training personnel and may be used to assist in making an accept/reject decision. 2.2 Process Control Manufacturing steps which might affect finished part appearance shall be prepared to enable compliance with this cosmetic specification. 2.3 Viewing Conditions. All parts and products shall be inspected under the following conditions:- a) Uniform non-directional illumination between 80 and 150 foot-candles should be used for normal inspection viewing condition at light levels greater than 150 foot-candles, caution should be used to not over-inspect. b) Viewing distance shall be 400mm (16") or 450mm (18") or 600mm (24") as per specified by surface class. c) Viewing angle by 45 ± 15 for the light source. d) Inspection shall be conducted using the unaided eye. e) Magnification is not to be used when inspecting cosmetic defects. 2.4 Time and Distance Inspection. "Viewing Time" indicates the duration of the observation. The more critical the cosmetic surface, the longer the inspection period. "Viewing Distance" indicates how far the inspector will be from the parts. The more critical the cosmetic surface, the closer the inspector will be to the parts. Parts shall be inspected in accordance with instructions and codes on the part drawing. If the drawing references this specification the codes will reference Table I "Viewing Time and Distance". On drawings referencing this specification, surfaces not cosmetically coded shall be considered IIIC. 2.5 Cosmetic Nomenclature and Grading A code that consists of a Roman numeral (category) and an alpha character (class) designate the cosmetic requirement for a surface. Cosmetic surfaces are ranked first by the final location on the part/product and then secondly by the frequency that an end-user views the part/product surface.

3 Document Reference: MISB-MACIS-Rev (1) Page 3 of 13 The definitions for category and class are indicated as below: Category Description Class Observation Frequency I External Windows A Usually Viewed II External s B Seldom Viewed III Internal s C Not Visible D Structural Category "I" is used exclusively for critical areas of clear windows (areas continuously viewed by an end-user when operating the end product) Category "II" is generally specified for front panels or exterior surfaces of an assembly. Class "II-A" would indicate a very critical surface, where "II-B" might be used to indicate an important surface, but less so than "II-A" & "II-C" would indicate not critical whereby the surface might be hidden or not visible after assembly Category "III" is generally specified for interior frames and chassis not visible in the final assembly. Although it could be visible during installation or maintenance The lowest cosmetic designation would be "III-D", which is basically "no requirement" for beauty. Table 1. Cosmetic inspection Viewing Time & Distance per designated area or surface Code I-A II-A II-B II-C III-B III-C III-D Application External Windows External External External Internal Internal Internal Structural Viewing Distance 400mm (16in) 450mm (18in) 450mm (18in) 600mm (24in) 450mm (18in) 600mm (24in) N/A Viewing Time of Area 10 seconds 10 seconds 5 seconds 3 seconds 5 seconds 3 seconds sq. mm (50 sq. in.) sq. mm (50 sq. in.) sq. mm (100 sq. in.) sq. mm (100 sq. in.) sq. mm (100 sq. in.) sq. mm (100 sq. in.) N/A Note: Class I-A, II-A & II-B surfaces shall be manipulated during inspection to achieve maximum reflection of a light source. Class II-C, III-B & III-C surfaces shall NOT be manipulated during inspection.

4 Document Reference: MISB-MACIS-Rev (1) Page 4 of 13 Viewing Conditions for I-A, I II-A & II-B. Light Source = 80 ~ 150 Foot Candles at Part Inspection Time I-A & II-A = 10 Seconds II-B = 5 Seconds Part Viewing Angle = 45 ± 15 Viewing Distance I-A = 400mm (16") II-A & II-B = 450mm (18") Manipulate Viewing Conditions for II-C, III-B & III-C. Light Source = 80 ~ 150 Foot Candles at Part Inspection Time III-B = 5 Seconds II-C & III-C = 3 Seconds Part Viewing Angle = 45 ± 15 Viewing Distance III-B = 450mm (18") II-C & III-C = 600mm (24") Do NOT Manipulate 2.6 Accept/ Reject Decision. When flaws are observed within the specified time and distance and the accept/reject decision is difficult to make, refer to Cosmetic Reference Standard Table. Parts are often cosmetically acceptable even though flaws are noticeable.

5 Document Reference: MISB-MACIS-Rev (1) Page 5 of Repetitive Inspection. A flaw that occurs repeatedly in the same surface location becomes more easily noticed. If this same cosmetic flaw was judged acceptable at the beginning of the run or lot inspection it shall also be acceptable at the end. 2.8 Reference Dimensions Dimension locating cosmetic areas designated by phantom lines are "reference" and should not be measured. 3.0 Cosmetic Inspection Specification for Sheet Metal Parts. Table 2 lists flaws typically found on sheet metal parts. This table constitutes the reference standard of cosmetic acceptability. The total number of allowable mixed flaws shall not exceed the limit specified for the flaw with the for the flaw with the largest allowable quantity limit. Table 2 is primarily used to train personnel involved in inspection and may be used to assist in making accept/reject decision. Table 2. Cosmetic reference standard for sheet metal parts. Flaws per I-A II-A II-B III-B II-C & IIIC Cracks See Note Discoloration Fracturing Qty : 1 Gouges Qty : 1 0.8mm (.03") Scratches Qty : 1 0.1mm X 3.2mm (.004" X.13") 0.1mm X 12.7mm (.004" X.50") 0.2mm X 75mm (.008" X 3") Qty : 3 0.3mm X 100mm (.012" X 4") Marks & Pits Qty : 1 0.8mm (.03") Tooling Marks Acceptable Acceptable

6 Document Reference: MISB-MACIS-Rev (1) Page 6 of 13 Dent & Ding Qty (3) Max. dents of less than 0.04" diameter per 50 Sq in. On edge of part: Qty (1) Max Length:.125" Max Depth: 0.03" Qty (3) Max. dents of less than 0.04" diameter per 50 Sq in. Qty (1) Max Diameter:.125" Max Depth: 0.03" Note: Should not affect the Class A or B side of the part Fingerprints Note: if part surface is coded CLASS II-C or III-C flaws exceeding those allowed under Class III-B are permitted; however when viewed at the specified time and distance the flaws must not be so obvious as to suggest inferior workmanship or processing. Defect Definitions: Cracks :- Separation into the cross-section at folds that meet to produce a closed corner. Discoloration :- Any change from original color, intended color or inconsistent color. Fracturing :- Separation of metal on the outside surface of a fold. Gouges :- Indentation that can be felt. Scratches :- Shallow grooves. Marks :- Sanding or other marks on base material that remain visible after coating. Pits :- Small craters on the surface. Tooling marks :- Normal process marks created by forming dies. These marks are consistent on all parts and located at the formed area. All other marks are not defined as standard tooling marks. Depth of tooling mark can be visible but cannot be felt with thumbnail. Dent / Ding :- Indentation cause by handling. No surface penetration. 4.0 Cosmetic Inspection Specification for Coated / Plated / Painted Parts. Table 3 lists flaws typically found on sheet metal parts. This table constitutes the reference standard of cosmetic acceptability. The total number of allowable mixed flaws shall not exceed the limit specified for the flaw with the largest allowable quantity limit. Table 3 is primarily used to train personnel involved in inspection and may be used to assist in making accept/reject decision.

7 Document Reference: MISB-MACIS-Rev (1) Page 7 of 13 Table 3. Cosmetic reference standard for Coated / Plated / Painted Parts. Flaws per I-A II-A II-B III-B II-C & IIIC Discoloration, Glossiness and Specks See Note Lint / Scratches 0.3mm X 0.8mm (.01" X.03") 0.5mm X 2.3mm (.02" X 0.9") Qty : 3 0.5mm X 6.4mm (.02" X.25") Marks / Run 0.5mm X 1.3mm (.02" X.05") 0.5mm X 1.3mm (.02" X.05") Non-Adhesion and Non-uniform Coverage Qty :4 Oxidation / Rust Tooling Marks Acceptable Acceptable Fingerprints Note: if part surface is coded CLASS II-C or III-C flaws exceeding those allowed under Class III-B are permitted; however when viewed at the specified time and distance the flaws must not be so obvious as to suggest inferior workmanship or processing. Defect Definitions: Discoloration :- Any change from original color, intended color or inconsistent color. Glossiness :- An area of excessive or deficient gloss. Specks :- Small particles. Lint :- Any unintended foreign substance in the coating or on the surface. Scratches :- Shallow grooves. Marks :- sanding or other marks on base material that remain visible after coating. Run :- Excessive coating that causes drips. Non-Adhesion :- Lack of proper sticking of the coating to the surface. Non-Uniform Coverage :- Areas that have an insufficient or excessive coating. Run :- Excessive coating that causes drips.

8 Document Reference: MISB-MACIS-Rev (1) Page 8 of 13 Oxidation / Rust :- Chemical reaction of exposed metal with oxygen. Tooling marks :- Normal process marks created by forming dies. These marks are consistent on all parts and located at the formed area. All other marks are not defined as standard tooling marks. Depth of tooling mark can be visible but cannot be felt with thumbnail. 5.0 Cosmetic Inspection Specification for Printed Parts. Table 4 lists flaws typically found on sheet metal parts. This table constitutes the reference standard of cosmetic acceptability. The total number of allowable mixed flaws shall not exceed the limit specified for the flaw with the largest allowable quantity limit. Table 4 is primarily used to train personnel involved in inspection and may be used to assist in making accept/reject decision. Table 4. Cosmetic reference standard for Printed Parts. Flaws per I-A II-A II-B III-B II-C & IIIC Smearing See Note Bleeding & Haze Scratches 0.3mm X 0.8mm (.01" X.03") 0.5mm X 1.3mm (.02" X 0.5") 0.5mm X 6.4mm (.02" X.25") Discoloration / Voids / Specks & Fill in 0.8mm (.03") 1.3mm (.0.5") Flow Marks 0.5mm X 1.3mm (.02" X 0.5") 0.5mm X 1.3mm (.02" X.05") Non-Adhesion and Non-Uniform Coverage Qty :4 6.4mm (.25") Inconsistency 1.3mm (.0.5") Note: if part surface is coded CLASS II-C or III-C flaws exceeding those allowed under Class III-B are permitted; however when viewed at the specified time and distance the flaws must not be so obvious as to suggest inferior workmanship or processing.

9 Document Reference: MISB-MACIS-Rev (1) Page 9 of 13 Defect Definitions: Smearing :- The presence of ink on the area not called for by the drawing or artwork. Bleeding :- The evidence of one color usually altering another where they overlap. Haze :- A discoloration or dullness of a surface that prevent a clear reflection of light. Scratches :- Shallow grooves. Discoloration :- Any change from original color, intended color or inconsistent color. Voids :- Unfilled areas on printed or screened surface. Lack of ink. Specks :- Small particles. Fill in :- An excess of ink that alters the form of a screened feature not affecting legibility. Flow Marks :- Wavy or streaked appearance of a surface. Non-Adhesion :- Lack of proper sticking of the coating to the surface. Non-Uniform Coverage :- Areas that have an insufficient or excessive coating. Inconsistency :- Variation of gloss, thickness of line or surface texture not called for by drawing or artwork. 6.0 Cosmetic Inspection Specification for Machined Parts. Table 5 lists flaws typically found on sheet metal parts. This table constitutes the reference standard of cosmetic acceptability. The total number of allowable mixed flaws shall not exceed the limit specified for the flaw with the largest allowable quantity limit. Table 5 is primarily used to train personnel involved in inspection and may be used to assist in making accept/reject decision. Table 5. Cosmetic reference standard for Machined parts. Flaws per I-A II-A II-B III-B II-C & IIIC Contamination See Note Discoloration Nicks, Dents & Gouges Qty : 1 0.8mm (.03") Non-Uniform Machine Marks 90% Uniform 0.1mm (.004") Max Height 50% Uniform 0.1mm (.004") Max Height Scratches 0.1mm X 0.8mm (.004" X.03") 0.2mm X 12.7mm (.008" X.5") Qty : mm X 25.4mm (.010" X 1.0")

10 Document Reference: MISB-MACIS-Rev (1) Page 10 of 13 Porosity Note: if part surface is coded CLASS II-C or III-C flaws exceeding those allowed under Class III-B are permitted; however when viewed at the specified time and distance the flaws must not be so obvious as to suggest inferior workmanship or processing. Defect Definitions: Contamination :- Residues, coolants, lubricants, corrosion or deposits or organic growths from processing or storage environments. Discoloration :- Any change from original color, intended color or inconsistent color. Nicks, Dents & Gouge :- Marks, Indentations or depressions. Non-Uniform Machine Marks :- Abrupt changes in surface appearance caused by tools (raised marks areas, ridges and burrs.) Scratches :- Shallow grooves Porosity :- holes or voids. 7.0 Cosmetic Inspection Specification for Die Cast Parts. Table 6 lists flaws typically found on sheet metal parts. This table constitutes the reference standard of cosmetic acceptability. The total number of allowable mixed flaws shall not exceed the limit specified for the flaw with the largest allowable quantity limit. Table 6 is primarily used to train personnel involved in inspection and may be used to assist in making accept/reject decision. Table 6. Cosmetic reference standard for Die Cast parts. Flaws per I-A II-A II-B III-B II-C & IIIC Growth Qty : 1 See Note Heat Checking and Sink Max. Depth : 0.2mm (.008") Max. Depth : Max. Depth : 1mm (.04") Porosity, Protrusions and Specks 0.8mm (.03") Qty : 6 Scratches 0.25mm X 0.8mm (.01" X.03") 0.5mm X 3.2mm (.02" X.13") Qty : 3 0.5mm X 6.4mm (.02" X.25")

11 Document Reference: MISB-MACIS-Rev (1) Page 11 of 13 Dent & Ding Not acceptable except on edge of part. Qty (1) Max Length:.125" Max Depth: 0.03" Qty (3) Max. dents of less than 0.04" diameter per 50 Sq in. Qty (1) Max Diameter:.125" Max Depth: 0.03" Note: Should not affect the Class A or B side of the part Weld Lines Max. Depth : 0.1mm (.004") Max. Depth : 0.15mm (.006") Max. Depth : 0.2mm (.008") Note: if part surface is coded CLASS II-C or III-C flaws exceeding those allowed under Class III-B are permitted; however when viewed at the specified time and distance the flaws must not be so obvious as to suggest inferior workmanship or processing. Defect Definitions: Growth :- Expansion of casting from aging. Heat Checking :- Fine crack, veins, or fins of any length. Sink :- A depression on a surface (shrink Mark). Porosity :- Holes or voids (blow holes, pit and under-fills) Nicks, Dents & Gouge :- Marks, Indentations or depressions. Protrusions :- A raised area on a surface (blister, bump, ridge). Specks :- Small particles. Scratches :- Shallow grooves Weld Lines :- A visible line or mark on a surface of any length. 8.0 Cosmetic Inspection Specification for Plastic Parts. Table 7 lists flaws typically found on sheet metal parts. This table constitutes the reference standard of cosmetic acceptability. The total number of allowable mixed flaws shall not exceed the limit specified for the flaw with the largest allowable quantity limit. Table 7 is primarily used to train personnel involved in inspection and may be used to assist in making accept/reject decision. Table 7. Cosmetic reference standard for Plastic parts. Flaws per I-A II-A II-B III-B II-C & IIIC Burns and Protrusions See Note

12 Document Reference: MISB-MACIS-Rev (1) Page 12 of 13 Pits and Specks Qty : 8 Scratches 0.3mm X 0.8mm (.01" X.03") 0.5mm X 2.3mm (.02" X.09") 0.5mm X 6.4mm (.02" X.25") Sink Marks 0.8mm (.03") Weld Lines 3.0mm (.125") 6.4mm (.25") 12.7mm (.13") Abrasion marks Dent & Ding Max. Diameter : 6.4mm (.25") Not acceptable except on edge of part. Qty (1) Max Length:.125" Max Depth: 0.03" Acceptable Qty (3) Max. dents of less than 0.04" diameter per 50 Sq in. Qty (1) Max Diameter:.125" Max Depth: 0.03" Note: Should not affect the Class A or B side of the part Color Variations Acceptable Note: if part surface is coded CLASS II-C or III-C flaws exceeding those allowed under Class III-B are permitted; however when viewed at the specified time and distance the flaws must not be so obvious as to suggest inferior workmanship or processing. Defect Definitions: Protrusions :- A raised area on a surface (blister, bump, ridge or gate mark). Burns :- Black specs in the surface pf the part due to overheating. Discoloration :- Any change from original color, intended color or inconsistent color. Flow Marks :- Wavy or streaked appearance of a surface. Haze :- Cloudiness on an otherwise transparent part. Pits :- Small craters on the surface. Specks :- Small particles. Scratches :- Shallow grooves Sink :- A depression on a surface (shrink Mark). Weld Lines :- A visible line or mark on a surface of any length. Abrasion Marks :- Un-intended mark caused by contact/rubbing to the part. Does not have depth.

13 Document Reference: MISB-MACIS-Rev (1) Page 13 of 13 Dent / Ding :- Indentation cause by handling. No surface penetration. Color Variations :- Color of part appears different from color sample chips. 9.0 Manufacturing Tolerances Hole to Hole (on flat) ±0.15mm (per machine tool manufacture) Edge to Hole ±0.30mm Edge to Edge ±0.40mm Fold to Hole ±0.40mm Fold to Edge ±0.40mm Fold to Fold ±0.50mm Angles ±1 Hole sizes ±0.08mm 10.0 Tolerance on Thickness The tolerance on thickness shall be as given in the table below; these tolerance apply over the whole length of the sheet. Material thickness: Tolerance >0.40 to < 0.60 ±0.06 >0.60 to < 0.80 ±0.07 >0.80 to < 1.00 ±0.08 >1.00 to < 1.20 ±0.09 >1.20 to < 1.60 ±0.11 >1.60 to < 2.00 ±0.13 >2.00 to < 2.50 ±0.15 >2.50 to < 3.00 ±0.17 Prepared by: KL Lee Reviewed by: SH Ang Approved by: Daniel Ong Date: 24 Sept 2009 Date: 24 Sept 2009 Date: 24 Sept 2009