qop-07-17 appearance workmanship standards - … · operational procedures page 1 of 22 qop-07-17...

Operational Procedures of 22

QOP-07-17 – Workmanship Standards for Appearance Revision: A

nAll oAdmin oEng oMFG oQA oPurch oSales oShip oTech

Originator Jerry Lamothe

Date: 8/11/2010

Approver Charlie Breen

Date: 8/11/2010

Comark Corporation Company Confidential

Purpose

The purpose of this standard is to define and establish acceptance and rejection criteria for surface finish for incoming and outgoing inspections. The inspection purpose is to determine any conditions for which a part or system will be rejected. The intent of inspection is:

· To ship a part or system that meets this finish standard.

· It is NOT intent of inspection to find all imperfections on a part or system.

Application

This standard applies to approved Suppliers or Subcontractors, Customers, and Comark Corporation. This standard applies to Surface Finishes such as Paint, Plating, Molding and silk-screening.

Associated Documents

QOP-08-09, Process/Product Deviation Procedure

Document History

Revision Reason for Change Author Rev. A First Release (August 11, 2010) Jerry Lamothe





Date: 8/11/2010


Date: 8/11/2010


Table of Contents Purpose........................................................................................................................... 1

Application ...................................................................................................................... 1

Associated Documents.................................................................................................... 1

Document History ............................................................................................................ 1

Standard for Appearance Quality .................................................................................... 3

1. Paint...................................................................................................................... 3

1.1. Preferred ................................................................................................... 3

2. Silk-Screening ....................................................................................................... 3

2.1. Preferred ................................................................................................... 3

2.2. Tape Pull Test ........................................................................................... 3

3. Plating ................................................................................................................... 4

3.1. Preferred ................................................................................................... 4

4.1. Acceptable Defects for Class “A” Surfaces ................................................ 4

4.2. Acceptable Defects For Class “B” Surfaces ............................................... 5

4.3. Acceptable Defects for Class “C” Surfaces ................................................ 6

4.4. Acceptable Defects for Class “D” Surfaces ................................................ 7

4.5. Acceptable Defects For Class “E” Surfaces ............................................... 8

5. Inspection Requirements ...................................................................................... 8

5.1. Viewing Conditions .................................................................................... 8

6. Surface Categories ............................................................................................... 9

7. Light Source .......................................................................................................... 9

7.1. Light Specification ..................................................................................... 9

7.2. Light Intensity ............................................................................................ 9

7.3. Light position ............................................................................................. 9

7.4. Inspection Table Surface ........................................................................... 9

8. Viewing Time ...................................................................................................... 10

8.1. Class A .................................................................................................... 10

8.2. Class B .................................................................................................... 10

8.3. Class C .................................................................................................... 10

8.4. Class D .................................................................................................... 10

8.5. Class E .................................................................................................... 10

9. Viewing Orientation ............................................................................................. 10

10. System Surfaces ................................................................................................. 11

10.1. Classification System Surfaces ............................................................... 11

11. Viewing Tools ...................................................................................................... 11

11.1. Magnification Tools .................................................................................. 11

12. Viewing Distance................................................................................................. 11

12.1. Class A .................................................................................................... 11

12.2. Class B .................................................................................................... 11

12.3. Class C .................................................................................................... 11

12.4. Class D .................................................................................................... 11

12.5. Class E .................................................................................................... 11

13. LCD Display Guidelines ...................................................................................... 12

13.1. Class of Display ....................................................................................... 12

13.2. Defect type classification ......................................................................... 12

13.3. Maximum permissible defect table ........................................................... 14





Date: 8/11/2010


Date: 8/11/2010


13.4. Measure method/control conditions for pixel defects ............................... 14

14. LCD Window Cosmetic Specifications ................................................................ 15

14.1. Lighting environment ............................................................................... 15

14.2. Inspection Method ................................................................................... 15

14.3. Inspection Procedure ............................................................................... 15

14.4. Evaluation Method ................................................................................... 16

14.5. For Windows With Viewing Areas > 2 Square Feet. ................................ 16

14.6. For Windows With Viewing Areas < 2 Square Feet ................................. 17

15. Comark Corporation Internal Inferior Workmanship Escalation ........................... 17

15.1. If this Workmanship Standard does not identify a defect ......................... 17

15.2. Escalation Process .................................................................................. 17

16. Order of Precedence ........................................................................................... 18

17. Terms and Defect Definitions .............................................................................. 18

18. References ......................................................................................................... 22

18.1. Department of Defense ........................................................................... 22

18.2. IPC .......................................................................................................... 22

18.3. ISO13406-2 and ISO 9431-307, Class II ................................................. 22

18.4. View Thru Technologies Cosmetic Specification ..................................... 22

Standard for Appearance Quality

1. Paint

1.1. Preferred

Painted surfaces should be defect free and the texture and color should be uniform throughout the entire surface.

The finish on a continuous surface shall exhibit no gross imperfections such as gouges, large chips, runs, blisters, oil spots, flaking, or any defects that will affect the functional properties of the finish.

Paint touch-up is acceptable.

A touch-up is not acceptable if visible at the viewing distance for that class of surface.

2. Silk-Screening

2.1. Preferred

Silk-screened logos or symbols should be defect free, and should withstand cleaning with mild solvents and the tape pull test.

2.2. Tape Pull Test

The tape pull test is a non-destructive test of silk-screened parts. Use a 3M Scotch Brand #600 for all silkscreen pull tests.

This tape is common used by the industry due it is close to matching the specifications callout in ASTM D3359-76: “Measuring Adhesion by Tape Test”, 36+/- 2.5 oz/in





Date: 8/11/2010


Date: 8/11/2010


2.2.1. Tape pull test procedure

· Smooth tape into place by finger

· Within 90 sec +/-30 sec of applying the tape, remove by seizing the free end pulling it off rapidly back upon itself, as close to an angle of 180 degrees as possible.

· Inspect the tape and the tested area for removal of paint

3. Plating

3.1. Preferred

Visible outside surfaces should be defect free, and die and slug marks should not be visible.

The finish shall have uniform appearance;

Visual appearance will vary between different alloys and between machined, milled, cast, and grained surfaces.

Outside surface shall be free from scratches, dents, or gouges.

4. Acceptable Defects Matrix

4.1. Acceptable Defects for Class “A” Surfaces

Viewing time Viewing distance Ten (10) seconds per 200 square inches per part, Five (5) seconds per 50 square inches

for front panels 24 Inch (610 mm)

DEFECT ACCEPT REJECT

Bleed out Up to 5/16” away from seam.

Touch up allowed. Any greater than 5/16”

Blister None Any

Blush Accept per approved engineering

document.

Bubble None Any

Burns Accept per approved engineering

document.

Burrs Less than 10% of material

thickness Any greater than 10%

Cloudiness None Any

Contamination None Any

Corrosion / Rust / Oxidation None Any

Cracks None Any

Dent / Ding / Pitting None Any

Discoloration color consistency

Accept per approved engineering document for 100% uniformity of

surface. Partial discoloration

Dirt / Lint / Specks / Smudge

Less than or equal to 0.02” Any greater than 0.02”

Flash Accept per approved engineering

document.

Flow Marks None Any





Date: 8/11/2010


Date: 8/11/2010


DEFECT ACCEPT REJECT Fingerprints None Any

Flaking / Chipping / Peeling None Any

Metal Fuzz None Any

Paint Non-Adhesion / Non-Uniformity / Inconsistency

None Any

Paint runs None Any

Scratches / Gouges Qty. 3, less than or equal to 0.01”

x 0.03”

More than qty. 3. Any bare metal or base metal on a painted

surface

Scuff Marks Accept per approved engineering

document.

Short-Shots None Any

Sink Less than or equal to 0.003deep Any greater than 0.003”

Smearing None Any

Spot weld, Welding Lines Accept per approved engineering

document.

Texture / Gloss / Finish 100% uniformity of surface,

Accept per approved engineering document.

Partial variation

Tooling marks / Die marks / Slug mark / Punch mark /

Burnish marks


Voids Less than or equal to 0.01” Any greater than 0.01”

Water Spots None Any

4.2. Acceptable Defects For Class “B” Surfaces

Viewing time Viewing distance Seven (7) seconds per 200 square inches per

part 30 Inch (760 mm)




Blister None Any


document.

Bubble None Any

Burns Accept per approved engineering document.



Cloudiness None Any

Contamination Qty. 1, Less than or equal to

0.03” More than qty. 1 per surface or

any greater than 0.03”


Cracks None Any


Discoloration color consistency Non-Uniformity

90% uniformity of surface. More than 10% surface

discoloration or consistency


Qty. 3, Less than or equal to 0.03”

More than qty. 3 per surface or any greater than 0.03”

Flash Less than or equal to 0.005” in

height Any greater than 0.005” in height

Flow Marks None Any





Date: 8/11/2010


Date: 8/11/2010


DEFECT ACCEPT REJECT Fingerprints Surface 99% fingerprint free More than 1% of the surface

Flaking / Chipping / Peeling Less than or equal to 0.03” Any bare metal greater than 0.03”

or any exposed base metal

Metal Fuzz None Any

Paint Non-Adhesion / None Any

Paint runs None Any

Scratches / Gouges Qty. 2; Less than or equal to

0.02” x 0.09”; Qty. 1; Less than or equal to 0.01” x 0.25”;

More than limit qty. per surface. Any exposed base metal on

painted surfaces


document.


Sink Less than or equal to 0.005” deep Any greater than 0.005” deep

Smearing None Any

Spot weld, Welding Lines Less than or equal

to 0.005” in height or depth Any greater than 0.005” in height

or depth

Texture / Gloss / Finish Less than or equal to 0.02” x

0.25” Any greater than 0.02” x 0.25”


Burnish marks




4.3. Acceptable Defects for Class “C” Surfaces

Viewing time Viewing distance Five (5) seconds per 200 square inches per





Blister None Any


document.

Bubble None Any


document.



Cloudiness None Any





Cracks None Any



80% uniformity of surface. More than 20% surface discoloration or

consistency






Flow Marks None Any





Date: 8/11/2010


Date: 8/11/2010



Flaking / Chipping / Peeling Less than or equal to 0.09” Any bare metal greater than0.09”


Metal Fuzz None Any

Paint Non-Adhesion Non-Adhesion

None Any

Paint runs None Any

Scratches / Gouges

Qty. 4; Less than or equal to 0.02” x 0.25”; Qty. 1; Less than or equal to 0.01” x 0.5”; More than

limit qty. per surface.

Any exposed base metal on painted surfaces


document.


Sink Qty. 1, Less than or equal to

0.015” deep Any greater than 0.015” deep

Smearing None Any

Spot weld, Welding Lines Less than or equal

to 0.005” in height or depth Any greater than 0.005” in height

or depth



Tooling marks / Die marks /Slug mark / Punch mark /

Burnish marks




4.4. Acceptable Defects for Class “D” Surfaces

Viewing time Viewing distance Five (3) seconds per 200 square inches per





Blister None Any


document.

Bubble None Any


document.



Cloudiness None Any





Cracks None Any

Dent / Ding / Pitting Less than or equal to 0.09” in

depth Any greater than 0.09”


70% uniformity of surface. More than 30% surface

discoloration or consistency








Date: 8/11/2010


Date: 8/11/2010





Flow Marks None Any

Fingerprints Surface 90% fingerprint free More than 10% of the surface

Flaking / Chipping / Peeling Less than or equal to 0.09” Any bare metal greater than 0.09”


Metal Fuzz None Any

Paint Non-Adhesion None Any

Paint runs Qty. 1, Less than or equal to

0.02” x 0.5” More Than qty.1 or any greater

than 0.02” x 0.5”

Scratches / Gouges Less than or equal to 0.02” x

0.25”; Qty. 3; Less than or equal to 0.01” x 0.5”;

More than limit qty. per surface. Any exposed base metal on

painted surfaces


document.


Sink Qty. 1, Less than or equal to

0.03” deep Any greater than 0.03” deep

Smearing None Any

Spot weld, Welding Lines Less than or equal to 0.005” in

height or depth Any greater than 0.005” in height

or depth




Burnish marks Any

Any exposed base metal on painted surfaces



4.5. Acceptable Defects For Class “E” Surfaces

Viewing time Viewing distance Unspecified Unspecified


Metal Fuzz None Any


document.

Cosmetic Flaws All kinds of touchup allowed

Any flaw that impacts the functionality of the part. Any

exposed base metal on painted surfaces. Defective corrosion

protection.

5. Inspection Requirements

5.1. Viewing Conditions

The inspector shall scan the surface in a continuous manner. All judgments shall be made from the specified lighting, viewing distance, angle and material classes as described below.





Date: 8/11/2010


Date: 8/11/2010


6. Surface Categories

Class Description Applications

A

Always visible. A critical cosmetic surface usually front exterior surfaces which are most often closely viewed by the user /

customer

· Faceplates

· Control Panels

· Enclosure Doors

· Any silkscreened surface

B

Usually visible. Is a semi-critical cosmetic surface usually exterior surface which is

adjacent to Class A, not viewed as often but easily seen.

· Enclosures (exterior)

· Parts 3’-10’ of eye view

C

Seldom visible. Is a non-critical cosmetic surface either exterior surfaces rarely viewed by the user/ customer, such as back surface;

or an internal surface that is visible but not normally viewed by the user / customer

· Enclosures (Interior)

· Brackets

· Parts > 10’ of eye view

· Corrosion prevention only

D

Not visible. Is a non-critical cosmetic surface usually exterior surfaces normally not viewed

by the user / customer, such as a bottom surface or a back of a panel.

E Unclassified. Non-cosmetic surface usually never seen by a customer or if surface is

customer classified as non-cosmetic surface

· All parts that cannot be viewed in an assembled condition

· Parts that will be discarded at customers location (shipping protection)

· Customer specified

7. Light Source

7.1. Light Specification

White, cool artificial office lighting (e.g. fluorescent light)

CAUTION: Do not use direct sunlight.

7.2. Light Intensity

Uniform intensity between 70 and 120 foot-candles. (750 and 1250 Lux)

At levels of greater light intensity caution should be used to not over inspect

the parts in order of accentuate surface flaws.

7.3. Light position

Reflection free, non-directional from the top.

No direct overhead light above inspection table.

7.4. Inspection Table Surface

The table surface should be made of a non-reflective dark color to avoid twilight conditions.





Date: 8/11/2010


Date: 8/11/2010


Preferred: Black rubber mat Acceptable: Dark blue rubber mat Unacceptable: Light color table surfaces e.g. white, gray, yellow, metallic etc.

Reflective light-colored surfaces eliminate or accentuate surface flaws.

8. Viewing Time

8.1. Class A

Systems: Ten (10) seconds per 200 square inches per part

Front Panels: Five (5) seconds per 50 square inches per part

8.2. Class B

Seven (7) seconds per 200 square inches per part

8.3. Class C

Five (5) seconds per 200 square inches per part

8.4. Class D

Three (3) seconds per 200 square inches per part

8.5. Class E

Unspecified

9. Viewing Orientation

· During inspection, view objects in an orientation perpendicular to each surface. During assembly, view objects in normal orientation of manufacturing process. In some cases inspection should be held prior to assembly.

· Any visible surface flaw has to be verified against the acceptable defect matrix.

Parts shall not be manipulated to reflect a single light source in order to

accentuate surface flaws.





Date: 8/11/2010


Date: 8/11/2010


10. System Surfaces

10.1. Classification System Surfaces

Type/Style Front Top Side Back Bottom Inside

DESKTOP A B B C D Invisible E Visible C

RACKMOUNT B C C C D Invisible E Visible C

SUBRACKS B C C C D Invisible E Visible C

CABINET B C B C D Invisible E Visible C

PRODUCT CASES

A B B C D Invisible E Visible C

EXTRUDED PARTS AND HANDLES

Anodize B Painted B

Anodize C Painted C

Anodize C Painted C

Anodize C Painted C

Anodize D Painted D

Invisible E Visible D

11. Viewing Tools

11.1. Magnification Tools

Magnification tools may be used to find root causes for defects or to verify correctness of special areas.

Magnification is not to be used when inspecting for cosmetic defects.

12. Viewing Distance

Viewing Distances from the surface being inspected

12.1. Class A

24 Inch (610 mm)

12.2. Class B

30 Inch (760 mm)

12.3. Class C

36 Inch (910 mm)

12.4. Class D

36 Inch (910 mm)

12.5. Class E

Unspecified





Date: 8/11/2010


Date: 8/11/2010


13. LCD Display Guidelines

13.1. Class of Display

Class 0 Applied to uses like medical imaging-type products where high sensitivity and importance to minimize risk in the information perception is critical.

Class I Applied to specific video display tasks where high sensitivity and special importance to pixel faults is less risky. This is the Comark standard Class.

Class II General User display tasks like reading and process text information where reading performance is not inhibited by pixel defects.

Class III

For display tasks with less sensitivity to pixel faults like processing public information and advertisement, text book reading, or fast moving images where defective pixels do not cause discomfort to the User.

13.2. Defect type classification

13.2.1. Type 1 Hot pixel (always on, white, aka high state)

13.2.2. Type 2 Dead pixel (Always off, black, aka low state)





Date: 8/11/2010


Date: 8/11/2010


13.2.3. Type 3 Stuck pixel (either red, blue, or green, always on or off)

13.2.4. Type 4 Faulty clusters (5x5 pixels)

13.2.5. Other defects.

A different type of defect caused by microscopic contaminants within the manufacturing process can also be found. Contamination results in a dark "stain" covering one or several sub-pixels. They are not pixel or sub-pixel defects per say. No contamination is allowed under Comark policy.





Date: 8/11/2010


Date: 8/11/2010


13.3. Maximum permissible defect table

The following table defines the maximum permissible number of pixel faults for the respective resolution types validly for the pixel error Class I.

Maximum permissible number of errors for the pixel error Class I

in accordance with ISO 13406-2 and ISO 9241-307

Physical

Resolution

Number

of pixels

Type 1

Stuck High

Type 2

Stuck Low

Type 3

Stuck pixel

Cluster

fault

Type 1 &

Type 2

Cluster

fault

Type 3

XGA

1024 x 768 768,432 1 2 1 0 0

WXGA

1280 x 800 1,024,000 1 2 1 0 0

SXGA

1280 x 1024 1,310,720 2 3 2 0 0

UXGA

1600 x 1200 1,920,000 2 4 2 0 0

WUXGA

1920 x 1080 2,073,600 2 4 2 0 0

13.4. Measure method/control conditions for pixel defects

In observance of the ISO 13406-2 and ISO 9431-307 standards, the following conditions are considered:

· Final control for pixel fault done right after Burn-in, i.e. pre-heating of display.

· Ambient temperature ~ 77°

· Relative air humidity 40-70 %

· Viewing distance 24 inches.

· Ambient illumination of 300 to 500 lux

· Viewing angle of 70 to 110 degrees horizontal and 80 to 110 degrees vertical.

· Viewing duration ~30 seconds.





Date: 8/11/2010


Date: 8/11/2010


14. LCD Window Cosmetic Specifications

This document describes the inspection environment, procedures and acceptance

criteria for LCD windows.

14.1. Lighting environment

Two 4' GE F40-C50 fluorescent bulbs (or equivalent) shall be mounted above the inspection table and perpendicular to the inspector’s line of sight. Hanging at the rear surface of the inspection table, directly in front of the inspector, will be a black area and a white area. These are used as backgrounds during inspection. During inspections, the window may never be back-lit or edge-lit directly by the fluorescent bulbs. A light box shall be used for part of the inspection. The light box is composed of 4 F40-C50 fluorescent bulbs mounted behind a sheet of white acrylic (R&H 7447 or equivalent). Measurements are to be made with a contact reticle with 6-15X magnification (ref: Edmund Scientific 6X Pocket Comparator w/ Reticle #30-585, p/n 41-055

14.2. Inspection Method

Inspect the window through the viewing surface only. Disregard any blemishes within 0.060” of any machined edge.

14.2.1. For windows with a viewing area of < 2 ft2, the following inspections shall be conducted from a distance of 18 inches.

14.2.2. For windows with a viewing area of greater than 2 ft2, but less than 4 ft2, the following inspections shall be conducted from a distance of 48 inches.

14.2.3. For windows with a viewing area of greater than 4 ft2, the following inspections shall be conducted from a distance of 72 inches.

14.3. Inspection Procedure





Date: 8/11/2010


Date: 8/11/2010


14.3.1. Front Surface Inspection: Hold the window below and behind the light source and in front of the black background. Tilt the window to scan the reflection of the light bulb across the front surface. Look for defects while tilting the window.

14.3.2. Sub-Surface Inspection #1: Hold the window in the same location as in step A, but keep the window perpendicular to your line of sight. Look for defects while holding the window in that position.

14.3.3. Sub-Surface Inspection #2: Repeat step 14.3.2 in front of the white background.

14.4. Evaluation Method

14.4.1. Place the window on the light box.

14.4.2. Measure any blemishes identified in step A of the inspection procedure using the reticle.

14.4.3. View all blemishes identified in steps B and C of the inspection procedure from 18 inches directly over the window.

14.4.4. Disregard any blemishes which disappear under these conditions. Measure all other blemishes on the light table using the reticle.

14.4.5. During the measurement step, classify blemishes as circular or linear. Odd shaped blemishes are typically classified as circular. The diameter of an odd shaped blemish is the diameter of a circle with the same area. Use the sizes and quantities in the following tables to determine the acceptability of the window

14.5. For Windows With Viewing Areas > 2 Square Feet.

CIRCULAR BLEMISHES (blemishes less than 0.03" in length)

Diameter

Range &

Blemish Type

Minimum

Separation from

other Blemishes

Maximum Quantity

Allowed

(Translucent and

Opaque)

Maximum

Quantity of

Opaque Blemishes

Allowed

>0.020" &

£0.025" 2.0" 2 1

>0.010" &

£0.020" 1.0" 6 2

>0.005" &

£0.010" 0.5" Disregard Translucent 8

£0.005" N/A Disregard all Disregard all





Date: 8/11/2010


Date: 8/11/2010


LINEAR BLEMISHES (blemishes greater than 0.03" in length)

Maximum Thickness Maximum Allowed

>0.002" & £0.003" 0.2" cumulative length

£0.002" Disregard All

14.6. For Windows With Viewing Areas < 2 Square Feet

CIRCULAR DEFECTS (blemishes less than 0.05" in length)

Diameter

Range &

Blemish Type

Minimum

Separation from

other Blemishes

Maximum Quantity

Allowed per Window

(Translucent and

Opaque)

Maximum

Quantity of

Opaque Blemishes

Allowed per

Window

>0.030" &

≤0.040" 4.0”

0.5 per sq ft of

viewing area

0.25 per sq ft of

viewing area

>0.020" &

≤0.030" 2.0"

1 per sq ft of viewing

area

0.5 per sq ft of

viewing area

>0.015" &

≤0.020" 0.5”

3 per sq ft of viewing

area

1 per sq ft of

viewing area

>0.010" &

≤0.015" 0.1” Disregard Translucent

5 per sq ft of

viewing area

≤0.010" N/A Disregard all Disregard all

LINEAR BLEMISHES (blemishes greater than 0.05" in length)

Maximum Thickness Maximum Allowed

>0.002" & ≤0.003" 0.2" cumulative length per square foot of

viewing area

≤0.002" Disregard All

15. Comark Corporation Internal Inferior Workmanship Escalation

15.1. If this Workmanship Standard does not identify a defect

Every team member has to question inferior workmanship ONLY when you see a defect that is not clearly identified within this workmanship standard.

15.2. Escalation Process

When questioning a system or part for inferior workmanship issues follow this escalation process:

15.2.1. Locate the suspected defect

15.2.2. Check the Workmanship Standard, and any applicable engineering specifications





Date: 8/11/2010


Date: 8/11/2010


15.2.3. If no specification or special instructions are applicable, contact following support team members

· QC Team member

· Responsible Engineer

· Quality Manager

15.2.4. The Support team member must evaluate and make a decision on the suspected defect.

16. Order of Precedence

In case of a conflict between this Workmanship standard, Work Instructions, engineering specification or other applicable specifications, following hierarchy will apply:

· Approved Deviation

· Engineering Specification

· Work Instruction

· Workmanship Standard

17. Terms and Defect Definitions

Condition Definition/Description

Accept per approved engineering drawing

Some cosmetic imperfections are not avoidable in certain process and design circumstances. Approved engineering documents will point this out.

Abrasion Surface imperfection that doesn’t remove or displace material appears as a scuff or changes to the surface

finish.

Bare Metal A metal surface that has an intact protective coating but

no cosmetic finish.

Base Metal A bare metal surface on which the protective coating has

been compromised.

Bleed Out A Substance that runs out of seams. Color can vary from

brown, dark brown to gray white at plating.

Bleeding Rough and not densely packed dull gray lines at plated

material.

Blister A bubbling in the surface of the finish. Non-adhesion or

lack of proper sticking of the coating to the surface caused by trapped air, gas or moisture.

Blush Discoloration or change in gloss.

Burns Brown marks or streaks on a surface of the part caused

by trapped gases burning the surface of the plastic during molding operation.

Bubble A bubbling in the surface of the finish. Non-adhesion or

lack of proper sticking of the coating to the surface caused by trapped air, gas or moisture.





Date: 8/11/2010


Date: 8/11/2010



Bump Protrusions caused by trapped air / gas or moisture

usually seen in finished parts.

Burnish Marks Marks or lines that cannot be felt usually caused by tooling dies most common on flattened cold rolled

material e.g. Steel or aluminum sheets.

Burrs

Sharp edges around part features caused by manufacturing process like punching, shearing, milling or

drilling.

Sheet metal edges that are compliant to UL 1439 can still cut through protective gloves and/or human hands.

Chipping Areas in which the adhesion between the paint and the surface is poor, causing the paint to come off with light

rubbing.

Cloudiness A haziness or lack of clarity in otherwise transparent part.

Cluster (LCD Displays) 5x5 pixels

Contamination Rough and not densely packed dull gray lines at plated

material. Colored specks of foreign material embedded in or on the surface part.

Corrosion

Areas of corrosion on any metal surfaces.

Small areas of rust are acceptable where plating is removed by a standard manufacturing or welding

process, e.g. sheared (cut) edges.

Cracking

Crackled appearance due to poor adhesion usually from surface contamination before plating. Hairline cracks of anodized material caused by bending, high temperature curing after silk screening of the aluminum or tool mark hair cracks on the opposite site of the aluminum. Some

cracks can’t be avoided. Fine damages which may extend in a pattern on or beneath the surface or through a layer

of material.

Crazing A fine mesh of minute cracks on the surface of some

plastics due mainly to the effects of UV light.

Delaminating Separation, peeling of thin layer of material

Dent A surface depression caused by an impact.

Tooling marks are not dents.

Die marks Marks made on the metal’s surface when it is formed,

usually consist of long straight lines.

Ding Roughly funnel shaped dent caused by an impact.

Dirt Any particle of foreign material.

Discoloration Any change from the original color or shade in the finish.

Distortion A deformation of a die-casted part





Date: 8/11/2010


Date: 8/11/2010



Dust Small particles.

Fill In An excess of ink that alters the form of a screened

feature not affecting legibility.

Fingerprints An impression left on the surface due to operator

handling.

Finish An area of smoother finish of molded plastic parts.

Flaking Areas in which the adhesion between the paint and the surface is poor, causing the paint to come off with light

rubbing.

Flash Thin, excess material usually around the area of the mold

parting line or internal shutoff areas.

Flow Marks Waviness of edge or excess linear surface texture of silk-

screened areas.

Fracture Material splitting usually on the outside bend radius.

Gates Point at which plastic is injected in cavity, usually on

parting line.

Gloss A uniform appearance of a painted or molded area. E.g.

Shiny, matt

Glossiness An area of either excessive or deficient gloss.

Gouge A groove or scratch that extends through the finish and

into the metal caused by a sharp object. A depth is measurable.

Grease Any lubricant transferred to the part’s surface, shiny or

glossy patches on the surface of the part.

Haze Cloudiness on an otherwise transparent part.

Inconsistency Variation of gloss, thickness of line or surface texture.

Inclusions Small craters on surface caused by dust or dirt.

Lint Any unintended foreign substance in the coating or on the

surface.

Marbling Colored streaks on a surface caused by improper mixing

of molten plastic.

Marks Pits, sanding, or other marks on base material that

remains visible after coating.

Matt Finish A less glossy finish of a surface area.

Metal Fuzz Fine grit metal shavings that are clumped together, may

also be magnetic.

Nicks Like gouges but short of length caused by impact.

Non-adhesion Lack of proper sticking of the coating or a glued material

to the surface.

Non-uniform Coverage Areas that have an insufficient or excessive coating.





Date: 8/11/2010


Date: 8/11/2010



Oils Oily material on the surface due to materials used in

manufacturing processes. Oily looking spots caused by Loctite locking feature.

Orange Peel Paint defect, rippled or mottled appearance viewable as concentric lines caused by under pressurizing not dried

paint surfaces.

Orange Skin Paint defect, rippled or mottled appearance.

Oxidation Has a rough feel of appearance. Dull gray, dark gray, black, brown, dark cinnamon or possibly white colored

substance.

Peeling Areas in which the adhesion between the paint and the surface is poor, causing the paint to come off with light

rubbing.

Pixel A full pixel is a combination of one red, one green, and

one blue sub-pixel

Pitting Small craters on surface.

Punch mark Mark on the surface of a material due to punch process.

Runs Drips, bleeding, visible lines or raised areas of excessive

paint or chemical coating similar to non-uniform coverage.

Rust

Areas of corrosion on any metal surfaces.

Small areas of rust are acceptable where plating is removed by a standard manufacturing or welding

process, e.g. sheared (cut) edges.

Scratch A shallow groove that can be seen but not felt.

Scuff marks A series of very light, concentrated scratches that can be

seen but not felt.

Short-Shot Incomplete molded feature.

Sink Depression or dimple caused by non-uniform material

shrinkage.

Slug Mark A surface deformity caused by the punching process.

Smearing The presence of ink on areas not called out in the master

artwork.

Smudge Any dirt particle of foreign material.

Specks Small particles.

Spot Weld Mark

Dish shaped surface caused by spot welding process. Preferred workmanship is homogeneous spot weld

marks.

Spot weld marks are not avoidable. Black residue occurs during plating process.





Date: 8/11/2010


Date: 8/11/2010



Tooling Marks

Very shallow lines that are parallel to bends in part. Unwanted impact of a tool during punch process.

Some tooling marks are not avoidable in some process steps. E.g. punching, forming, bending.

Texture An area of rougher finish of plastic molded parts. A

rougher but uniform finish of painted parts.

Visible Surface Surfaces those are visible when the enclosure or part is

installed in a completed assembly.

Void The failure of ink to define a graphic feature.

Warpage Dimensional distortion in a part after molding, pressing or

laminating. Twist or bows in the part.

Water Spots Rough and not densely packed dull gray lines at plated

material.

Weld lines Line where molten plastic or metal joins form a part. A weld line usually appears as a noticeable line or gloss

variation across the surface of the part.

18. References

18.1. Department of Defense

DOD Preferred Methods Of Acceptance Of Products, MIL-STD-1916 Classification Of Visual And Mechanical Defects For Equipment, Electronic, Wired, And Other Devices, MIL-STD-252 Classifications Of Characteristics, DOD-STD-2101

18.2. IPC

Acceptability of Electronic Assemblies, IPC-A-610

18.3. ISO13406-2 and ISO 9431-307, Class II

Guidelines for LCD pixel defects

18.4. View Thru Technologies Cosmetic Specification

# 3120000 (See 49-12238-001)