PPG Industries, Inc. · NYSE:PPG
PPG Industries — Technical Presentation (2022)
72 slides from PPG Industries's technical presentation, May 13, 2022
Slide 1: We protect and beautify the world
We protect and beautify the world
Slide 2: PPG Global Supplier Webinars – Technical Training
PPG Global Supplier Webinars – Technical Training
Slide 3: Technical Training Agenda
Technical Training Agenda Supplier Quality Requirements Adila Cizmic / Ruth Zorrilla / Luisa Gutierrez Incoming Raw Material Quality John Hargreaves Contamination Prevention Benjamin Benito / Jean Pierre Strinati Q&A 3
Slide 4: Expectations and Take Aways
Expectations and Take Aways Q&A Awareness Partnership Questions sent via Slido Deploy the information shared Work together and collaborate during the session within your to reduce quality risk. were integrated to the organization. Help us to Have a closer and open presentations. You can prevent qual
Slide 5: PPG Automotive Supplier Quality Requirements
PPG Automotive Supplier Quality Requirements Luisa Gutierrez – Supplier Development Manager EMEA
Slide 6: PPG Supplier Quality Requirements
PPG Supplier Quality Requirements SUPPLIER PORTAL TRAINING AND AWARENESS Supplier QMS Requirements → * MAQMSR Expectations, including Customer Requirements → Change notification → COA Requirements → Supplier Audit Process Contamination Prevention → Bulk Transport Requirements → Packaging Policy → Gl
Slide 7: PPG Supplier Quality Requirements
PPG Supplier Quality Requirements Accessible to all the suppliers: https://corporate.ppg.com/Purchasing/PPG-Supplier-Network/PPG-Auto-OEM-Supplier-Quality.aspx
Slide 8: Supplier QMS Development – MAQMSR
Supplier QMS Development – MAQMSR
Slide 9: What is the IATF 16949?
What is the IATF 16949? Global Industry Standard created by the International Automotive Task Force ( certification Introduction bodies, auditors, suppliers and OEMs). It harmonizes the different assessments and certification systems in the global automotive supply chain. PPG is IATF 16949 certified
Slide 10: Supplier QMS Progression
Supplier QMS Progression What are the MAQMSR? ****Minimum Automotive Quality Management System Requirements*** SUPPLIER SUPPLIER SUPPLIER It is a guideline developed by FCA and Ford and it • IATF169 MAQM ISO 9001 is intended to be used by Tier 1 suppliers to SR 49 3rd party cert. develop lower Tier
Slide 11: Supplier Audit Process
Supplier Audit Process
Slide 12: Supplier Audit Process
Supplier Audit Process Audit Objectives Audit Planning Questionnaire Approve Potential (Scope) (Data collection) Suppliers Develop Current Suppliers Educate Suppliers on PPG specific requirements AUDIT Confirm ISO/IATF Requirements Check effectiveness of corrective/preventive Actions Results actions
Slide 13: Supplier CAIR, Root Cause Analysis & Supplier Portal
Supplier CAIR, Root Cause Analysis & Supplier Portal Global Webinar Adila Čizmić Mehmedović - Supplier Development EMEA
Slide 14: What does CAIR stand for?
What does CAIR stand for? & When do we use the CAIR system? Tracking System • C – orrecting •Non-Conformities • A – djustment • Consolidated communication channel CAIR • I – ncident • R - eporting • Data Source • Consistency in problem solving • Trend analysis PPG closes PPG opens CAIR when Suppl
Slide 15: Why do we use the CAIR system?
Why do we use the CAIR system? IATF 16949 IATF16949 Section 8.4.2.4 • • Supplier for Product conformity IQC¹ metrics, audit the Supplier to requirements results Automotive Monitoring IATF 16949 Standard • Supplier CAIR – Industry PPG Scorecards quality, delivery, and documentation Customer • Supplie
Slide 16: How do our suppliers access the CAIR System?
How do our suppliers access the CAIR System? Two ways of Access accessing E-Mail address Internet E-Mail Browser invitation Sent by e-mail from suppliernetwork@ppg.com „PPG Supplier Network“
Slide 17: What happens with the responses?
What happens with the responses? Supplier Portal View Root Cause Rensposiveness CAIR Database View Automatic update in the CAIR system
Slide 18: CAIR Types and Severity
CAIR Types and Severity CAIR Typology CAIR Severity 0 - Praise Compliment • Documentation errors You are doing a great job! 1 - Minor • For record only 1 - Incident Internal Documentation of non-conformity Supplier CAN respond 2– • PPG affected or Repeat • Escalate if chronic Important 2 - Alert Sup
Slide 19: 8D: What is it & where does it come from?
8D: What is it & where does it come from? 8D • Ford Motor Company Analyzing & problem solving tool • Team Oriented Problem Solving 8 Disciplines (TOPS) • 1980 Defining Root Causes Origins Devising short-term fix solution Implementing long-term solution to prevent recurring problems D1 Cross- functio
Slide 20: What should be taken into consideration regarding 8D?
What should be taken into consideration regarding 8D? PPG opens a CAIR Severity 1 & 2 Severity 3 & 4 Closure within 8D 60 days D1 – D3 D4 D5 – D8 Corrective & Interim fix Root Cause Preventive Actions Corrective Within 48 Preventive 90 days to fully Within 30 days Actions within hours within 60 days
Slide 21: Supplier Delivery Requirements
Supplier Delivery Requirements Global Webinar Ruth Zorrilla – Supplier Development Manager LATAM
Slide 22: Documentation Requirements
Documentation Requirements CERTIFICATE OF ANALYS (COA) 01 Must be sent 24 hours in advance of the delivery Up load data into the system Check for specification Issues BULK TRANSPORTATION Cleaning Certificate 02 CHAMP CODE In All documents 03
Slide 23: COA Must Have
COA Must Have Manufacturer name and location Example PPG CHAMP code PPG PO number Manufacturing Date Expiration date Specification and test methods Summary test results, include type of inspection (EN 10203 or equivalent) If recertify material new Expiry date
Slide 24: Shelf life requirements
Shelf life requirements Any material shipped into a PPG facility Shall have a Or a minimum Any material minimum of of 6 months, out of 50% of for shelf life specification remaining values will be rejected shelf life exceeding 1 year
Slide 25: Delivery Requirements
Delivery Requirements Lots / delivery <= 2 Mixed Pallets Segregated and identified Antistatic packaging policy Bags grapping is mandatory New Package Notification is mandatory
Slide 26: PPG Change Notification Requirements for Suppliers
PPG Change Notification Requirements for Suppliers Notification is required for changes: Must have a system for 1 changes management • Raw material new or existing supplier • Process equipment or parameters • Any change in formulation or ingredients level • Manufacturing site 2 Notify PPG at least 9
Slide 27: Incoming RM Quality
Control of Incoming Quality COA Incoming RM Quality Entry Sampling Testing Approval Global Webinar John Hargreaves – Raw Material & QA Manager
Slide 28: Incoming RM Quality: CofA Receipt
Incoming RM Quality: CofA Receipt COA Sampling Testing Approval Entry PPG Champcode Approved Supplier Check: Dropdown box lists approved Suppliers for each raw material. The Supplier is selected during the COA entry
Slide 29: Incoming RM Quality: CofA Data Entry
Incoming RM Quality: CofA Data Entry COA Sampling Testing Approval Entry PPG Internal Specifications
Slide 30: Incoming RM Quality: Risk and Testing Matrix
Incoming RM Quality: Risk and Testing Matrix COA Sampling Testing Approval Entry Major Risk Factors: Quality History Active Formulas and Profitability Contribution Shelf Life and Transportation Risk
Slide 31: Incoming RM Quality: Sampling Methods
Incoming RM Quality: Sampling Methods COA Sampling Testing Approval Entry Tank Wagon Sampling Drum Sampling
Slide 32: Incoming RM Quality: Chemical Conformity Testing
Incoming RM Quality: Chemical Conformity Testing COA Sampling Testing Approval Entry NIR Identity and Conformity Testing
Slide 33: Level 2 Failure
Level 2 Failure RM-1 S1602T1208 Max CI value: 6.23 Points Out: 446 Investigation: Supplier added 2% butanol due to a stuck valve which caused slightly higher MW. Disposition: Approved for use by technical. Suspect Lot
Slide 34: Incoming RM Quality: Contamination Testing
Incoming RM Quality: Contamination Testing COA Impact of PDMS on OEM Coatings Sampling Testing Approval Entry Examples of Dirt and Gel Tests Examples of Contamination Tests
Slide 35: Incoming RM Quality: Approval / Rejection
Incoming RM Quality: Approval / Rejection COA Sampling Testing Approval Entry Approval Rejection
Slide 36: Contamination Prevention
Contamination Prevention Jean-Pierre Strinati - Quality Manager Automotive France Benjamín Benito - Quality Assurance Manager Spain & Portugal
Slide 37: Contamination Prevention
CONTAMINATION PREVENTION P.01 Introduction, Know the threat IT'S TIME TO LEARN ABOUT CRATERS / CONTAMINATION, AND WHY WE SHOULD P.02 Identify the contaminants ELIMINATE THEM. P.03 Eliminate the contaminants INTRODUCTION, KNOW THE THREAT P.04 Summary
Slide 38: Introduction, Know the threat
P.01 Introduction, Know the threat Contamination that causes craters continues to be one of the biggest issues in Automotive Coatings Crater investigations have identified contamination sources in our raw material, transport, maintenance, production processes and all over our supply chain Awar
Slide 39: What is a crater? What do craters look like?
What is a crater? Craters are dish shape deformations in a paint surface caused by the presence of a low surface tension contaminant. It is also called a ‘fish eye’. The difference in the surface tension of the contaminant and the surface tension of the coating causes the paint to ‘crawl’ away from
Slide 40: Crater contamination at an automotive site
Crater contamination at an automotive site The presence of low surface tension contaminants causes craters Contamination could be in the paint, in the atmosphere or on the surface of the vehicles being painted Even very small quantities of the contaminant in the paint can cause craters - less than 0
Slide 41: Contamination Prevention: Identify the contaminants
CONTAMINATION PREVENTION LEARNING TO IDENTIFY P.01 Introduction, Know the threat CONTAMINANTS IS ESSENTIAL TO ELIMINATE CRATERS. P.02 Identify the contaminants IDENTIFY THE P.03 Eliminate the contaminants CONTAMINANTS P.04 Summary
Slide 42: Identify the contaminants
P.02 Identify the contaminants Contaminant can be all over the entire supply chain Risk Analysis is needed to stop them Crater contaminants are a destructive threat that can hide in a wide range of chemicals. You must check, test and verify any chemical product before using it because, in many cases
Slide 43: Chemical Families That Can Cause Craters
CHEMICAL FAMILIES THAT CAN CAUSE CRATERS & SEVERE CRATERS P.02 Identify the contaminants
Slide 44: High level of threat chemical families
These are three of the key chemical families that can cause craters: 1. Petroleum based oils and greases LEVEL OF THREAT: Some materials in this category cause craters, depending on the structure of the oil and the additive used to enhance the properties. HIGH 2. Detergents and defoamers These mater
Slide 45: Extreme level of threat chemical families
These two chemical families can cause SEVERE craters. Therefore, they are our greatest enemies: LEVEL OF THREAT: 1. Silicones (polysiloxanes) Polysiloxanes are popular ingredients in a large range of EXTREME maintenance materials, release agents, personal care products (lotions, anti-perspirants, ha
Slide 46: Where do we encounter these ingredients?
WHERE DO WE ENCOUNTER THESE INGREDIENTS? P.02 Identify the contaminants
Slide 47: Maintenance Materials
MAINTENANCE MATERIALS Maintenance and engineering areas depend on the use of a wide range of oils, greases, waxes and chemical compounds that have a low surface tension to keep the machines running LUBRICANTS SEALANTS CUTTING OILS ADHESIVES Agitator gear Valve Cutting steel in Used to cement boxes,
Slide 48: Consumables Materials
CONSUMABLES MATERIALS All molded or extruded products can be a source of contamination since their production involves the use of GASKETS RUBBER BANDS NITRILE DRUM (LARGE SIZE) GLOVES FAUCETS silicones (one of our Used in fittings Used to secure plastic Used to draw greatest enemies!) as to connect
Slide 49: Filters and Packing
Consumables are materials used in manufacturing, re-packaging and at our customer sites, and they are a potential threat due to the materials used in their production. FILTERS PACKING Filament and cartridge type filter Braided pump packing. media used to strain liquids. Some brands are coated with s
Slide 50: Road Tankers or Tank Wagons Used for Bulk Transport
ROAD TANKERS OR TANK WAGONS USED FOR BULK TRANSPORT If the wagons are not dedicated then the prior contents (solvents, resins, …. ) can become crater contaminants. Hoses, fittings, gaskets, valves associated with the wagons can potentially be contaminated – if new or not cleaned properly. Tank Wagon
Slide 51: Steel Totes, Steel Drums and Pails
STEEL TOTES Craters have come from contaminated caustic residue that was not rinsed adequately during the cleaning process. STEEL DRUMS AND PAILS Additives used in the lining of a pail or drum have leached into PPG products and caused craters. THREAT: • New container lining not tested before approva
Slide 52: Personnel Related Sources
PERSONNEL RELATED SOURCES Contaminants can be anywhere, even in ourselves! That’s why we must be extra careful of the products we use: • Personal Hygiene products: Lotions, deodorants, hair sprays, etc. • Lens cleaners. • Gloves and work wear fabrics. P.02 Identify the contaminants
Slide 53: Contamination Prevention: Eliminate the contaminants
CONTAMINATION PREVENTION NOW THAT YOU KNOW TO P.01 Introduction, Know the threat IDENTIFY CONTAMINANTS. IT’S TIME TO ELIMINATE THEM P.02 Identify the contaminants ELIMINATE THE CONTAMINANTS P.03 Eliminate the contaminants P.04 Summary
Slide 54: How do we prevent crater causing contamination?
P.03 Eliminate the contaminants Everything would be easier if we could test the paint for craters !!!, we can but …. There are some problems We need an homogeneous sample, is the contaminant evenly distributed ?, we do our best to take representative samples when we check for contamination, but we d
Slide 55: Maintenance Controls
MAINTENANCE CONTROLS P.03 Eliminate the contaminants
Slide 56: Supplier Sites: Ask to Fulfill 3 Simple Steps
SUPPLIER SITES Our suppliers shall have the same quality standards that PPG applies indoors; they must be informed of any actualization in the Materials Registration List (MRL) of approved products and chemicals. ASK TO FULFILL 3 SIMPLE STEPS: 1. Supplier compiles list of maintenance and production
Slide 57: Maintenance Controls for Equipment
MAINTENANCE CONTROLS FOR EQUIPMENT All new or repaired equipment or parts in the production areas must be pre-cleaned and purged with solvent, afterwards the solvent rinse must be tested for craters. FOLLOW 3 EASY STEPS: 1. New equipment purchased for use in the production area, like valves, is lock
Slide 58: Controls for Totes and Containers
CONTROLS FOR TOTES AND CONTAINERS P.03 Eliminate the contaminants
Slide 59: Steel Totes, Steel Drums and Pails Controls
STEEL TOTES FOLLOW 3 EASY STEPS: Tote cleaning All maintenance Before filled with paint, totes sites are audited materials used must be are sampled and tested for every year. tested and approved. craters. REMEMBER: Samples can be tricky, we must be alert for any threat. STEEL DRUMS AND PAILS Recycle
Slide 60: Bulk Transport Controls
BULK TRANSPORT CONTROLS P.03 Eliminate the contaminants
Slide 61: Prior Contents, Cleaning, Sampling and Testing
PRIOR CONTENTS All road tanker or tank wagon carriers for PPG (inbound or outbound) must adhere to our prior CLEANING contents rules. Prohibited prior contents have been identified and published for our suppliers and carriers. Cleaning station shall be EFTCO approved (or PPG approved) Cleaning sites
Slide 62: Housekeeping
HOUSEKEEPING P.03 Eliminate the contaminants
Slide 63: Housekeeping is crucial to reduce crater contamination risk
Housekeeping is crucial to reduce the risk of crater contamination in our sites: Control of dirt, oils, greases must be built into site procedures. Housings, connectors, ducts, filters and pipes should be kept as clean as possible. But before applying any cleaning procedure we must: Check that the C
Slide 64: Personnel Related Controls
PERSONNEL RELATED CONTROLS PERSONAL CARE PRODUCTS, WORKWEAR & FOOD P.03 Eliminate the contaminants
Slide 65: Personal Care, Workwear, Food
PERSONAL CARE As we have said before, crater contaminants are a deceivious threat All employees involved in production areas must verify that their that can hide in ourselves. That’s why each process should be personal care products are approved. You can’t just trust in the assessed for risks relate
Slide 66: 10 Golden Rules
10 GOLDEN RULES P.03 Eliminate the contaminants
Slide 67: 10 Golden Rules
10 GOLDEN RULES 5 3 1 4 2 I only use personal hygiene I always use approved work- products approved as I follow the crater wear in areas of production, crater-free. prevention process and laboratories and applications. I do not enter productive I do not introduce food to procedures. Crater risk area
Slide 68: Contamination Prevention: Summary
CONTAMINATION PREVENTION NOW THAT YOU KNOW WHAT IS P.01 Introduction, Know the threat NECESSARY TO ELIMINATE P.02 Identify the contaminants CONTAMINATION / CRATERS. LET’S PUT IT INTO PRACTICE REVIEW AND CHECK P.03 Eliminate the contaminants YOUR ABILITIES SUMMARY P.04 Summary
Slide 69: Summary
P.04 Summary Prevention is key - upstream at our Crater defects in our paint cost millions of suppliers and entire supply chain dollars and are caused by the presence of low surface tension contaminants. Numerous controls are needed Detection of contaminated for a strong prevention strategy. product
Slide 70: Contamination Prevention End
CONTAMINATION PREVENTION END Jean-Pierre Strinati strinati@ppg.com Benjamín Benito benito@ppg.com If any question or doubt please share with us
Slide 71: Q&A
Q&A
Slide 72: PPG – We protect and beautify the world
ppc We protect and beautify the world”