Automotive System

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 Agenda
• Lighthouse in Automotive, Thailand
• Real time monitoring system - Toyota Motor
Thailand (Gateway plant)
• Other opportunities

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 Detroit of Asia

Nagoya of Siam

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Paint Booth: Problems
Case Study: Auto Manufacturer
15 micron particles on the surface to
be painted will cause defects on the
final painted surface.
There are multiple layers in the
painting process. E.D. coat, primer,
two paint layers, and clear coat.
The 15 micron particle defect grows
with each paint coating, eventually
ending in a visible defect on the
surface of the car.

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Automotive Customer, Thailand

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Products sold
• Boulder Counter
• Environmental sensors
• Surface Scan Probe
• HH5016
• R50104 system with LMS express RT

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 Benefit of Particle Monitoring

• Seed defect - caused from dust or small particle

• Level of particle and clean area is unknown.
• Need equipment to measure and classify clean area to
improve quality.

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 Challenge
• Heavy weight
• Daily particle measurement
• 3 floors
• Repeatability and reliability of the data

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 System Diagram

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 System Demo to Toyota - painting

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 System Feature
• The demo system consists of
• 1 unit of R50104
• Particle size 5, 10, 50, 100 um
• Sampling locations: Top Coat Booth A – 2nd Floor
• 1 PC with real time monitoring software (LMS
Express 2006)
• Demo period from 4/24/09 – 5/21/09

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 System Diagram

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 Data of 5 um particle by day
5.0 micron Particle
16000
14000
12000
10000
8000
6000
4000
2000
0
09

09

09

09

09

09

09

09

5/ 9
9

4/ 9
9

4/ 9
9

5/ 9
9

5/ 9
9

5/ 9
9

5/ 9
9

9
0
/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0
1/

2/

3/

4/

5/

6/

7/

8/

9/
23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21
5/

5/

5/

5/

5/

5/

5/

5/

5/
4/

4/

4/

4/

4/

4/

5/

5/

5/

5/

5/

5/

5/
• Particle is high on the working day and low or zero on
non-working day (and/or no data collection day)
• Average particle counts per minute on working day is
1,000 - 2500 counts
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 Data of 10 um particle by day
10.0 micron Particle

1800
1600
1400
1200
1000
800
600
400
200
0
09

09

09

09

09

09

09

09

5/ 9
4/ 9
9

4/ 9
9

4/ 9

4/ 9
9

5/ 9
9

5/ 9
9

5/ 9

5/ 9
9

5/ 9
9

5/ 9
9
0
/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0

/0
1/

2/

3/

4/

5/

6/

7/

8/

9/
23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21
5/

5/

5/

5/

5/

5/

5/

5/

5/
4/

4/

4/

4/

5/

5/

5/

5/

5/
• Same trend as 5 um particle is observed, however 10 um
particle is less in count.
• Average particle per minute is 100 - 180 counts
• There is no particle size 50 and 100 um found during the
demo period.
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 •
•
•
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
4/23/09 4:17 PM
4/24/09 12:18 PM
4/24/09 2:25 PM
4/24/09 4:32 PM
4/24/09 6:39 PM
4/24/09 8:46 PM
4/24/09 10:53 PM
4/25/09 1:00 AM
4/25/09 3:07 AM

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4/25/09 5:14 AM
4/25/09 7:21 AM
4/25/09 9:28 AM
4/25/09 11:35 AM
4/25/09 1:42 PM
4/25/09 3:49 PM
4/27/09 9:26 AM
4/27/09 11:33 AM
4/27/09 1:40 PM
4/27/09 3:47 PM
4/27/09 5:54 PM
4/27/09 8:01 PM
4/27/09 10:08 PM
5.0 micron

4/28/09 6:03 AM
4/28/09 8:10 AM
4/28/09 10:17 AM
4/28/09 12:24 PM
4/28/09 2:31 PM

CONFIDENTIAL INFORMATION
4/28/09 4:38 PM
4/28/09 6:45 PM
4/28/09 8:52 PM
4/28/09 10:59 PM
4/29/09 1:06 AM
4/29/09 3:13 AM
Is this time match with Toyota working hour?
Low particle is observed during 1 AM to 7 AM

4/29/09 5:20 AM
4/29/09 7:27 AM
High particle is observed during 8 AM to 10 PM

4/29/09 9:34 AM
4/29/09 11:41 AM
Zoomed data from 4/24/09 – 4/30/09

4/29/09 1:48 PM
4/29/09 3:55 PM
4/29/09 6:02 PM
4/29/09 8:09 PM
4/29/09 10:16 PM
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16
 Recommendation
• It is recommend that the matching between the events
happened in the sampling area and particle count data
should be studied for painting process optimization
and improvement.
• It is recommended that the sampling probe location is
optimized to match with defective of the car and
reduce chance of damage to the particle counter.

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 Summary
• High Particle count can be observed during car
painting process using real time particle monitoring
system.
• With real time particle monitoring system, process
control and optimization could be achieved and results
in better product quality, less rework and higher
customer satisfaction.

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 Paint Shop Contamination Control Project
• Purpose
• To get approve from Top management about paint
shop contamination control project
• To improve system for contamination control
• To prevent dust from outside to paint shop.
• Background
• Current paint shop has 1 particle counter. It is heavy,
it can’t monitoring contamination real time, can
check dust only, not TRH.
• New technology remote particle counter can check
dust, TRH with real time monitoring

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 Paint Shop Contamination Control Project
• Conceptual
• Check dust, TRH at real time and alarm when over
target.
• Merit
• Improve environment of paint shop
• Control dust outside into paint shop.
• Can remove any contamination quickly.
• Can save cost effect from contamination (base on 1
defect).
• Labor cost = xxx Baht/defect
• Material cost = xxx Baht/defect

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 Identified 20 locations for particle monitoring;
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5 phases
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 Real time monitoring system
Toyota Motor Thailand (Gateway plant)

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System Diagram - Painting

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Sensor Location Map - Painting

Top Coat (B) Booth (Front)

Addr 01

Top Coat (A) Booth (Front)

Addr 02

Surfacer Night Storage

Surfacer Booth (Front)

Addr 04

Addr 03

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System Diagram - Resin

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Sensor Location Map - Resin

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 R50104

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 Hardware installation

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 Vacuum ejector (CDA to vacuum converter)
Use vacuum ejector pump, SMC model
ZH18DS-03-03-03, instead of vacuum
pump for cost reduction. CDA supply of
0.25-0.3 mpa 36.3- 43.5 PSI will provide
flow rate of 1.0 CFM

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 Current Status
• Painting contamination control project is set for 5
phases; 4 monitoring locations per phase.
• Installation for 1st phase is completed.
• Real time particle monitoring system maintenance
team is in place
• Setting up a contamination monitoring team for data
analysis
• Match contamination data to events and defects

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 Other Opportunities

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 Cleanliness Of Components
• Cleanliness requirements for certain components in the
automotive industry is dramatically rising. For example brake
systems and fuel-injection systems need to be fitted with
increasingly smaller diameters and they have to withstand
increasingly higher pressures. Therefore also a very minor particle
contamination may lead to big problems (the reliability and life
expectancy of that component).
• Due to the rising innovation speed the industry cannot afford to
identify possible failures at a relatively late stage. Therefore the
standard ISO 16232’Road Vehicles – Cleanliness of Components of
Fluid Circuits’ was developed for this area, describing methods
which can be used to control the compliance with the cleanliness
requirements.
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 ISO-16232 Road Vehicle - Cleanliness of
Components of Fluid Circuits.
ISO 16232-1 : Vocabulary
ISO 16232-2 : Method of extraction of contaminants by agitation
ISO 16232-3 : Method of extraction of contaminants by pressure rinsing
ISO 16232-4 : Method of extraction of contaminants by ultrasonic techniques
ISO 16232-5 : Method of extraction of contaminants by functional test bench
ISO 16232-6 : Particle mass determination by gravimetric analysis
ISO 16232-7 : Particle sizing and counting by microscopic analysis
ISO 16232-8 : Particle nature determination by microscopic analysis
ISO 16232-9 : Particle sizing and counting by automatic light extinction particle
counter
ISO 16232-10 : Expression of results

• Most of the automotives launch in CY2011 has specification for

components cleanliness
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 Thank You

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