QUALITY CONTROL

2013
www.skycoat.com/qc
SKYCOAT specializes in powder coating, conversion coating, and
media blasting.

SKYCOAT, LLC
Owner– Patrick Traynor
Quality Control Manager-Lacey Traynor
Production Manager-Terry Campbell
 SKYCOAT, LLC QUALITY CONTROL MANUAL

TABLE OF CONTENTS

QUALITY MANUAL PAGES 2-5

STANDARD OPERATING PROCEDURE 1 PAGE 6

STANDARD OPERATING PROCEDURE 2 PAGES 7-8

STANDARD OPERATING PROCEDURE 3 PAGE 9

STANDARD OPERATING PROCEDURE 4 PAGE 10

STANDARD OPERATING PROCEDURE 5 PAGE 11

STANDARD OPERATING PROCEDURE 6 PAGES 12-13

INSPECTION CRITERIA FOR CLASS “A” PAGE 14

INSPECTION CRITERIA FOR CLASS “B” PAGE 15

INSPECTION CRITERIA FOR CLASS “C” PAGE 16

WORK ORDER PROCEDURE SHEET (JOB SHEET) PAGE 17

TITRATION TEST PAGE 18

PAINTING PROCEDURE SHEET PAGE 19

SUPPLIER QUALIFICATION FORM PAGES 20-22

NEW EMPLOYEE TRAINING FORM PAGE 23

PREVENTATIVE AND CORRECTIVE ACTION FORM PAGE 24

MAINTENANCE SCHEDULE PAGE 25

A. INTRODUCTION:

a) PURPOSE

The purpose of this manual is to outline the structure that SKYCOAT,

LLC operates under to give our customers high quality work. This
manual is to be used by all employees as part of our quality
assurance program.

b) PROJECTION

Our quality assurance program consists of identification of parts

and material, packaging, storing and shipping.

c) GENERAL

This manual will describe the quality assurance program used by

SKYCOAT, LLC to act in accordance with specifications required by
customer contracts, sub-contracts and purchase orders. The policy
of SKYCOAT, LLC is to have quality assurance in all areas and
services purchased by us as well as parts produced by the company.

B. ORGANIZATIONAL STRUCTURE:

a) BACKGROUND

SKYCOAT specializes in powder coating, conversion coating, and media

blasting. Class A finishes on: aluminum, magnesium, and steel
parts. Pretreatments for: steel, aluminum, and magnesium.

b) SYSTEM ORGANIZATION

Owner– Patrick Traynor

Quality Control Manager-Lacey Traynor
Production Manager-Terry Campbell

C.QUALITY CONTROL

a) FORMS USED

Painting Procedure Sheet, Work Order Procedure Sheet (Job Sheet).

b) RESPONSIBILITIES

The quality control manager is responsible for the following:

aa) Explanation of customer requirements.

bb) Current drawings are updated and maintained in job folder.
Any obsolete documents are destroyed.
cc) Any parts sub-contracted will be inspected per specifications
of our shop and customer requests.
dd) Specific instructions provided for inspecting.
ee) All quality control records kept current.
ff) Marking and packing appropriately for customer shipping.
gg) SKYCOAT Quality Control maintains ongoing collaboration with
the customer and vendors to facilitate quality assurance.
2
 c) Vendor/Supplier Material Control- SKYCOAT materials are only
to be purchased from factory-approved distributors without
substitution of name brand product without notifying the
customer.
aa) Inspect incoming materials for: open containers, damages due
to shipping, and materials that are dated before the posted
shelf life expiration date.

D. PRODUCTION CONTROL

a) GENERAL

Production control is responsible for receiving customer

specifications and changes and notifying the production supervisor
immediately in the case of any required changes.

b) CHANGE CONTROL

Production control will be responsible for inspecting drawings and

instructions that are no longer in use. The drawings will be
destroyed or kept as record, which will be determined by Quality
Control.

c) ERRORS

SKYCOAT, LLC will act in accordance if an error is made and the

customer requests action. Changes will then be initiated and all
alterations will be filed using a corrective action form.

d) PURCHASE ORDER CONTROL

SKYCOAT, LLC will assign a work order process sheet (job sheet) for
each customer for each job in the order in which it is received.
The job sheet will have the lot number, part number, process, and
any revisions if applicable.

E. STOCK CONTROL

a) IDENTIFYING MATERIALS

All raw materials received by SKYCOAT, LLC will be inspected and

marked including:
aa) Date received
bb) Name of inspector - accept or reject
cc) Shelf life
dd) Type of material
ee) Company name

F. INSPECTION

a) RECEIVING INSPECTIONS/ Process Control

aa) All incoming shipments from customers are visually

inspected for damage during shipping.

b) IN-PROCESS INSPECTION:

3
 Quality assurance will be responsible for performing final
inspection. The painter will be responsible for his own work and
will check in process to ensure adherence to customer
specifications.

c) IN-LINE INSPECTION:

Parts in house will follow the job procedure sheet to be sure the
customer is receiving the highest quality part possible. Batch tests
are conducted to assure the gloss, color, texture, dirt, adhesion,
and mil thickness in accordance with customer requirements. A
detailed chemistry logged is recorded and filed for each lot number.

d) FINAL INSPECTION

Parts that do not pass final inspection will be checked by quality

assurance for scrap or rework. If part cannot be reworked, it is
labeled as discrepant and returned to the customer. Parts are
inspected based upon customer requirements and designated sampling
methods established by the quality control manager. Inspection
records are filed by quality manager and maintained for 7 years.

e) REJECT PROCESS

After final inspection any parts not fulfilling our quality

requirements according to the shop procedure sheet will be sent to
our rework area to solve the problem and send out a quality part.
Any parts that cannot be reworked will be sent to the discrepant
materials area, labeled discrepant, and shipped back to the customer.

G. MAINTENANCE SCHEDULE

a) EQUIPMENT MAINTENANCE

Equipment maintenance is performed in accordance with SKYCOAT

Quality Control (Maintenance log attached). If equipment is found
out of tolerance during calibration, products manufactured since
last calibration will be reviewed for discrepancies.

H. SPECIAL PROCESSES

Any special processes must be communicated to SkyCoat personnel via

phone or email and included on the purchase order. Special
processes will be documented on job sheet and accompany lot through
manufacturing. Any process we cannot fulfill at SKYCOAT, LLC will
be done at a place of origin approved by the customer.

a) MASKING/SANDING

Any parts needing masking or sanding will be sent to the

masking/sanding area. The parts will be inspected for any visual
defects and then masked or sanded according to customer’s
specifications.

I. COATERS

All coaters and paint mixers will follow the shop procedures sheet
4
 (included in the manual) while coating the product. The shop
procedure sheet is the detailed process for coating the product in
accordance with the customer’s specifications.

J. BAKING TIMES

Baking times and temperatures will comply with manufacturer’s

specifications.

K. QUALITY SYSTEMS MANAGEMENT PLAN

aa) Incoming product is inspected and assigned a job number.

bb) Quality specifications are referenced
cc) Caution is taken when handling products
dd) Specifications to follow are listed on job sheet including:
procedures for part #, purchase order, and manufacturing
process
ee) Quality is validated using the final inspection portion of
the Work Order Procedure Sheet
ff) Parts are stored in designated areas according to lot
numbers
gg) Outgoing parts are inspected according to Workmanship and
Inspection Criteria
hh) Outgoing parts are packaged according to specifications

L. Process Control

aa) Incoming product is labeled with lot number.

bb) Lot numbers are recorded on manufacturing floor job sheets
and travel through production with lot.
cc) Product is stored in designated area according to Lot
number and incoming/outgoing status.
dd) Discrepant materials are placed in the designated
discrepant materials area.

M. Supplies Procurement

SKYCOAT, LLC only purchases products from the qualified area

distributor. All suppliers must complete a supplier
qualification form.

N. Employee Training

All employees are required to undergo training to adhere to quality

requirements in the SKYCOAT, LLC manual. Training documents are
kept on record for each employee (New employee training checklist
attached).

O. Late delivery notification

In case of late delivery, the client will be notified via phone or

email.

5
SKYCOAT,)LLC.) ) ) Procedure)No:)SOP51)
Standard)Operating)Procedure) Page)
Title:) Revision:)1)
)))))) Non5conforming)products) ) Date:))10/22/12)
) Corrective)and)Preventative)action) )
)
This)Standard)Operating)Procedure)(SOP))describes)the)responsibilities,)procedures,)and)documentation)
for)reporting)non5conforming)product.))It)also)aims)to)prevent)non5compliances)within)the)management)
system,)address)customer)complaints,)and)request)improvements)to)processes.)
!
2.0!Responsibility!
The)Quality)Control)manager)is)responsible)for)the)quality)of)the)product/process)or)service)they)
provide,)the)prevention)and)correction)of)non5conforming)product/processes,)and)non5compliances.)
!
3.0!Procedures!
Non7!Conforming!Product!or!Process!
!
SKYCOAT)employees)are)authorized)to)identify)a)non5conformance)in)a)product)or)process)and)report)
the)issue)to)their)Quality)Control)Manager.)
)
For)non5conforming)product,)the)SKYCOAT)employee)records)the)non5)conformity)on)a)numbered)CAR)
and)indicates)the)root)cause)of)the)non5conformance.))
)
Non5Conforming)material)is)identified)by)a)label)and)moved)out)of)the)immediate)work)area)to)the")
discrepant)material")area.)
The)non5conformity)is)reviewed)and)resolved)by)working)with)the)Quality)Control)Manager.)The)
recipient)of)the)CAR,)the)CAR)number,)and)date)is)recorded)in)the)CAR)log.)
The)information)recorded)on)the)CAR)may)be)used)"As5Is",)rework,)or)discrepant.)The)final)resolution)of)
the)product)or)material)is)recorded)on)the)CAR)then)signed)and)dated)by)the)quality)manager.)
)
The)corrective)and/or)preventative)action)contains)sufficient)data)to)ensure)the)root)cause)of)the)non5
conformance)is)identified)and)changes)to)documented)procedures)are)made.)The)CAR)is)returned)to)the)
initiator)and)logged)accordingly.)
)
In)the)event)the)response)is)not)completed)in)a)reasonable)time)frame)or)the)planned)action)appears)
unlikely)to)address)the)root)causes)of)the)non5conformance,)the)initiator)opens)a)follow)up)CAR)and)
forwards)it)to)the)Owner)for)further)action.))
Preventive)actions)are)considered)to)be)long5term)processes)requiring)a)plan)of)action)based)upon)
analysis)of)the)factors)of)the)root)cause.)
The)purpose)of)the)CAR)is)to)display)the)basic)plan)of)action)needed)to)prevent)the)re5occurrence)of)the)
original)fault.)Each)step)of)the)plan)is)to)be)provided)with)a)monitoring)time)period.)
!
The)Quality)Control)Manager)is)responsible)for)undertaking)the)planning)of)preventative)actions)and)for)
implementing)the)actions)according)to)the)defined)program.)The)Quality)Control)Manager)is)responsible)
for)monitoring)the)planned)actions)and)for)providing)the)Owner)with)concise)summaries)of)the)progress)
of)the)plans.)
6
SKYCOAT,)LLC.) ) ) Procedure)No:)SOP52)
Standard)Operating)Procedure) Page)
Title:) Revision:)1)
)))))) Receiving)Control) Date:))10/22/12)
!
1.!0!Purpose!
!
This)Standard)Operating)Procedure)(SOP))describes)the)responsibilities,)procedures,)and)documentation)
for)receiving)and)control.)Additionally,)it)establishes)a)uniform)method)for)the)receipt)of)incoming)parts)
and)supplies.)
)
2.0!Responsibility!
!
The)Quality)Control)manager)is)responsible)for)receiving)and)control.)
Shipping)/)Receiving:)Verifies)incoming)material)and)packing)list)for)correct)purchase)order)number,)
correct)quantities,)and)material)type/alloy)or)part)number.)Ensures)all)necessary))material)certification)is)
supplied.)Contacts)vendors)and/or)customers)with)any)discrepancies.)
Quality)Department:)Inspects)all)material)for)correct)type,)dimensions,)and)verifies)that))
material)matches)supplied)specifications)and)print/job)requirements.)Contacts)vendors))
and/or)customers)immediately)with)any)discrepancies.)
)
3.0!Procedures!!
!
Receiving!
Any)qualified)employee)is)authorized)to)receive)shipments)of)parts)and)supplies.)Shipping)documents)
are)checked)to)verify)the)number)of)containers.)All)containers)or)material)is)checked)for)obvious)
damage)or)contamination.)(Obtain)record)of)damage)or)contamination)when)applicable)from)truck)
driver).))Items)listed)on)the)packing)slip)are)verified)to)be)included)in)the)shipment;)Discrepancies)are)
noted.)
)
In)the)event)that)material)is)damaged)in)shipment)to)SKYCOAT,)LLC,)the)Quality)Control)Manager)will)
work)out)the)liability)and)insurance)arrangements)with)carrier.)The)Quality)Control)Manager)will)notify)
owner.)
)
Upon)Receipt)of)an)incoming)lot)of)raw)material,)the)shipper/receiver)removes)the)supplier’s)packing)list)
and)obtains)the)corresponding)SKYCOAT,)LLC)purchase)order.)
)
The)shipper/receiver)reviews)the)purchase)order)for)specific)requirements)and)verifies)that)all)
requirements)have)been)met)(i.e.)quantities)match)packing)list)quantities)as)well)as)order)quantities,)
material)type)on)packing)list)matches)material)type)ordered,)required)specifications)have)been)supplied,)
correct)delivery)date,)etc.))
)
Control!
Materials/supplies)are)inspected)for)nonconformities)and)damage.)
Materials)identified)that)require)corrective)action)verifications)by)Quality)Control)are)segregated.)
Accepted)materials/supplies)are)moved)into)the)production)area)once)acceptance)is)granted)by)
Receiving)Inspection)
7
)
Inspection!
Dimensions)and)type)of)material)is)matched)to)purchase)order)and)packing)list)specifications.)
Raw)material)is)correctly)marked)and)easily)identified.)
Inspection)will)sign)or)stamp)acceptance)and)mark)the)date)of)acceptance)on)the)Material)Identification)
Tag).)
)
Inspected)materials)that)are)accepted)will)be)put)into)the)hold)area)pending)the)release)of))
the)job.))Once)released,)the)Production)Run)Packet)is)given)to)the)Production)
Control)Department)to)be)matched)up)with)the)tagged)material.))
)
Discrepant)materials)are)moved)to)the)designated)Discrepant)Materials)location,)tagged)with)a)red)tag)
and)a)CAR)form)is)filled)out)and)processed.)
Supplier)is)contacted)via)phone)or)email)regarding)discrepancy.)

8
)
SKYCOAT,)LLC.)) ) Procedure)No:)SOP53)
Standard)Operating)Procedure) Page)
Title:) Revision:)1)
)))))) Quality)in5process) ) Date:))10/22/12)
1.!0!Purpose!
This)procedure)ensures)that)all)activities)necessary)for)the)manufacturing)and)packaging)of)our)products)
is)planned)and)controlled)to)ensure)the)product)adheres)to)requirements)during)all)stages)or)processing.)

2.0!Responsibility!
The)Quality)Control)manager)is)responsible)for)the)overall)Quality)In5Process)and))
Final)Inspection.)
)
3.0!Procedures!!
In7Process!Inspection!/!Procedures!
In5Process)Inspection)will)be)performed)by)the)production)manager)and)recorded)on)job)sheet.)
Quality)Control)and)the)Production)Manager)will)determine)the)frequency)of)the)in5process)inspection.))
The)frequency)of)inspection)will)be)dependent)on)the)type)of)part,)cycle)time,)quantity)of)parts)to)be)
processed,)and)specification)provided)by)the)client.))Characteristics)to)be)inspected)will)be)determined)
by)Quality)Control)and)the)Production)Manager)for)each)job.))A)detailed)chemistry)log)is)recorded)and)
filed)for)all)production)lots.)))

In)the)event)of)a)reject)during)any)in5process)production,)the)rejected)part(s))will)be)clearly)identified)by)
a)red)tag)and)sent)to)the)discrepant)materials)area)separated)from)the)normal)flow)of)the)in5process)
materials.)

Rejected)part(s))will)follow)the)NON5CONFORMING)MATERIAL)CONTROLS)PROCESS)per)SOP)5)1.)

9
 )
SKYCOAT,)LLC.)) ) Procedure)No:)SOP54)
Standard)Operating)Procedure) Page)
Title:) Revision:)1)
)))))) Handling,)Packaging,)Storage,)and)Delivery) Date:))10/22/12)
!
1.!0!Purpose!
This)standard)operating)procedure)(SOP))provides)the)general)technical)requirements)and)operational)
guidelines)for)the)proper)labeling,)packing,)and)shipping)product.)These)Procedures)have)been)
developed)to)reduce)the)risk)of)damage.)

2.0!Responsibility!
The)Production)Manager)is)responsible)for)overall)implementation)of)this)procedure)and)ensuring)that)it)
complies)with)current)regulations)and)standards.)

3.0!Procedures!!
Handling!
Handling)procedures)shall)be)followed)to)prevent)damage)or)deterioration)of)materials)and)products.)

Storage!
Designated)areas)and)secure)stockrooms)shall)be)used)to)store)and)protect)material)
and)product.)Suitable)methods)for)authorizing)the)receipt)and)
dispatch)of)items)in)such)areas)shall)be)maintained)and)enforced.)Procedures)
detailing)the)identification)and)control)of)material)shelf)life)shall)be)followed)to)
ensure)that)expired)materials)or)components)are)not)used.)
!
Packaging!
Procedures)for)packaging,)packing,)and)the)identification)of)materials)and)products)shall)be)followed)to)
ensure)compliance)to)specified)customer)requirements.)Materials)are)to)remain)in)the)original)
manufacturer’s)package)when)possible.)
)
Delivery!
Packaging)materials)and)containers)will)be)inspected)to)make)sure)that)they)meet)customer)
specifications.))After)containers)are)sealed)and)before)they)are)shipped,)they)will)be)inspected)for)all)
applicable)marking)and)correct)shipping)information.)
)

10
 )
SKYCOAT,)LLC.)) ) Procedure)No:)SOP55)
Standard)Operating)Procedure) Page)
Title:) Revision:)1)
)))))) Non5conforming)products) ) Date:))10/22/12)
!
1.!0!Purpose!
!
This procedure establishes a system to inspect and ensure that all manufactured parts
meet customer specifications and include all required certificates,)samples,)and)other)
documentation.
)
2.0!Responsibility!
)
The)Quality)Control)Manager)performs)final)inspections.)
)
3.0!Procedures!!
!
Each)job)of)pieces,)parts,)or)sub5assemblies)must)be)final)inspected)before)being)transferred)to)the)
packaging)area.))

The final inspection is performed by verifying that all QC codes have been satisfied and all
required samples and certifications listed on the purchase order and job sheet are complete.
The inspection results are recorded on the Final Inspection Report, which is stored in the master
job folder in the front office.

Individual inspection reports will be made for each job inspected and filed according to
customer, part number, and date. The report will include part revision with each dimension
inspected, and the quantity accepted or rejected. Copies of Final inspection results will be
available for customer viewing in the front office or)the)QC)area.

Once jobs pass final inspection, they are routed QC approved on the job sheet and routed to
packaging.)

Parts or sub-assemblies that do not pass final inspection will be red tagged as discrepant and
routed to the discrepant materials area. Once labeled as discrepant, parts are returned to
client.

11
SKYCOAT,)LLC.)) ) Procedure)No:)SOP56)
Standard)Operating)Procedure) Page)
Title:) Revision:)1)
)))))) Supplier)Control) ) Date:))10/22/12)
!
1.!0!Purpose!
The)purpose)of)Supplier)Control)is)to)provide)quality)suppliers)to,)LLC)which)meet)all)expectations)for)
excellence)with)the)ultimate)goal)being)complete)customer)satisfaction.)
)
2.0!Responsibility!
The)Quality)Control)Manager)and)the)Production)Manager)are)responsible)for)final)inspections.)
)
3.0!Procedures!!
A)supplier)qualification)form)is)completed)by)each)new)vendor)to)evaluate)their)capability)as)a)potential)
supplier.)
)
The)supplier’s)ability)to)satisfy)requirements)is)reviewed)by)Purchasing)and)Quality)Control.)
)
Evaluation)may)include)one)or)more)of)the)following:)
! Ability)to)meet)requirements)
! Quality)Assurance)
! Price)
! Samples)Submitted)
! Lead)Times)
! References)
! Customer)Requirements)
)
NOTE:)If)the)product)or)service)is)a)customer)requirement,)no)further)evaluation)is)necessary.)
)
Prior)to)approving)a)supplier,)it)is)necessary)for),)LLC)and)the)supplier)to)clearly)communicate)to)all)
expectations)regarding)the)product)or)service)to)be)provided.)Any)unclear)specifications,)quality)
requirements,)or)other)issues)shall)be)resolved)prior)to)placing)the)supplier)on)the),)LLC)approved)
suppliers)list.)
)
Once)the)supplier)is)placed)on)the)approved)supplier’s)list,)their)performance)is)monitored)by)
Purchasing)and)Quality)Control)via)supplier)performance)reviews.))If)the)supplier’s)performance)is)
satisfactory,)they)continue)to)be)a)vendor.))Corrective)Action)for)unsatisfactory)suppliers)is)performed)as)
follows:)
Quality!Level!!!!!! ! Action!Taken! ! ! ! Supplier!Status!! !
1st)Reject) ) ) Phone)call)to)supplier) ) ) Approved)Supplier)
) ) ) ) noted)in)supplier’s)record)
)
2nd)Reject)in) ) ) Phone)Call)to)Supplier) ) ) Approved)Supplier)
12)Month)period) ) and)non5conformance)
issued.)

12
)
3rd)reject)in) ) ) phone)call)to)supplier) ) ) Conditional)Supplier)
12)Month)period) ) non5conformance)
) ) ) ) issued,)warning)letter)sent)
) ) ) ) and)supplier)reduced)to)
) ) ) ) conditional)status)
)
Out7Sourced!Processes!
)
Suppliers)of)out5sourced)processes)shall:)
! Meet)specifications)
! Perform)inspection)and)testing)to)verify)that)the)product)meets)specifications)
! Maintain)inspection)and)test)records)for)a)period)of)two)(2))years)
! Only)ship)products)to)that)meet)specifications)
! Provide)SKYCOAT)access)to)the)manufacturing,)packaging,)and)testing)facilities)upon)request)
)
NOTES:)
1.)Records)of)supplier)evaluations)and)correspondence)shall)be)kept)as)quality)records.)
2.)Supplier)non5conformities)are)resolved)in)accordance)with)the)corrective)action))
)))))procedures.)
3.)A)reject)is)defined)as)the)reject)of)one)(1))line)item)that)does)not)satisfy)quality)
)))))requirements.)
4.)Suppliers)that)have)not)been)used)for)a)period)of)three)(3))years)shall)be)re5evaluated)as)a)new)
supplier.)
)
)
) )

13
Workmanship,Standards,and,Inspecting,Criteria!
,
Purpose,
The!purpose!of!this!document!is!to!inform!the!customer!on!what!we!base!our!product!acceptability.!!If!
this!is!not!acceptable!with!you,!please!inform!us!in!writing.!!Otherwise,!these!are!the!criterion!we!will!be!
using.!
Inspection,Criteria,for,Class,“A”,
Class!“A”!products!are!ones!where!the!end!viewer!frequently!sees!the!product!
!
Inspection,methods,
View!at!a!distance!of!24”!in!normal!office!lighting!for!no!more!than!7!seconds!
!
Texture:! ! Should!be!uniform!
!
Scratches:! ! No!more!than!2!at!.010”!x!.030”!in!a!five!inch!square!
!
Runs:! ! ! None!allowed!
!
Gun!Spit:! ! No!more!than!3!at!.050”!diameter!maximum!in!a!two!inch!square!
!
Dirt,!Chips:! ! No!more!than!2!at!.020”!diameter!maximum!in!a!three!inch!square!
!
Gloss:! ! ! Can!vary!20%!
!
Cross!Hatch!
Adhesion!Test:! ! 80%!or!better!adhesion!
!
Porosity:! ! Not!responsible!for!defects!such!as!degassing!bubbles!and!pitting.!
,
General,Definitions,
,
Scratches! ! A!shallow!groove!or!line!on!the!surface!of!a!part!!
!
Lint! ! ! Fine!strands!of!fiber!covered!by!paint!
!
Dirt,!Dark!Specs!! Miniscule!particles!embedded!in!the!part!which!show!as!a!color!difference;!They!
are!most!often!sharp!topped!protrusions!above!the!painted!surface!
!
Gloss! ! ! A!surface!luster!on!the!finish!or!texture!
!
Flaking,!Peeling!! Areas!in!which!paint!comes!off!with!light!rubbing;!Very!poor!adhesion!between!
paint!and!part!
!
Chips! ! ! Areas!in!which!paint!has!been!knocked!loose!from!the!part!surface!
!
Paint!Runs! ! An!area!of!excess!paint,!which!has!“sagged”!or!flowed!to!a!noticeably!thicker!
height!
!
Gun!Spit! ! Clumps!or!globs!of!paint,!which!are!noticed!above!the!finish!or!texture!
14
Workmanship,Standards,and,Inspecting,Criteria!
,
Purpose,
The!purpose!of!this!document!is!to!inform!the!customer!on!what!we!base!our!product!acceptability.!!If!
this!is!not!acceptable!with!you,!please!let!us!know!in!writing.!!Otherwise,!these!are!the!criterion!we!will!
be!using.!
!
Inspection,Criteria,for,Class,“B”,
Class!“B”!products!are!ones!where!the!end!viewer!casually!sees!the!product!
!
Inspection,methods,
View!at!a!distance!of!40”!in!normal!office!lighting!for!no!more!than!4!seconds!
!
Texture:! ! Can!vary!30%!
!
Scratches:! ! No!more!than!2!at!.020”!x!.100”!in!a!five!inch!square!
!
Runs:! ! ! None!allowed!
!
Gun!Spit:! ! No!more!than!3!at!.075”!diameter!maximum!in!a!two!inch!square!
!
Dirt,!Chips:! ! No!more!than!2!at!.050”!diameter!maximum!in!a!three!inch!square!
!
Gloss:! ! ! Can!vary!30%!
!
Cross!Hatch!
Adhesion!Test:! ! 80%!or!better!adhesion!
!
Porosity:! ! Not!responsible!for!defects!such!as!degassing!bubbles!and!pitting.!
,
General,Definitions,
,
Scratches! ! A!shallow!groove!or!line!on!the!surface!of!a!part!!
!
Lint! ! ! Fine!strands!of!fiber!covered!by!paint!
!
Dirt,!Dark!Specs!! Miniscule!particles!embedded!in!the!part!which!show!as!a!color!difference;!They!
are!most!often!sharpZtopped!protrusions!above!the!painted!surface!
!
Gloss! ! ! A!surface!luster!on!the!finish!or!texture!
!
Flaking,!Peeling!! Areas!in!which!paint!comes!off!with!light!rubbing;!Very!poor!adhesion!between!
paint!and!part!
!
Chips! ! ! Areas!in!which!paint!ahs!been!knocked!loose!from!the!part!surface!
Paint!Runs! ! An!area!of!excess!paint,!which!has!“sagged”!or!flowed!to!a!noticeably!thicker!
height!
Gun!Spit! ! Clumps!or!globs!of!paint,!which!are!noticed!above!the!finish!or!texture!
!

15
!
,
Workmanship,Standards,and,Inspecting,Criteria,
,
Purpose,
The!purpose!of!this!document!is!to!inform!the!customer!on!what!we!base!our!product!acceptability.!!If!this!is!
not!acceptable!with!you,!please!let!us!know!in!writing.!!Otherwise,!these!are!the!criterion!we!will!be!using.!
,
Inspection,Criteria,for,Class,“C”,
Class!“C”!products!are!ones!where!the!end!viewer!does!not!see!the!product!
!
Inspection,methods,
View!at!a!distance!of!60”!in!normal!office!lighting!for!no!more!than!3!seconds!
!
Texture:! ! Can!vary!50%!
!
Scratches:!! ! Ok!as!long!as!it!is!not!through!the!substrate!
!
Runs:! ! ! Surface!must!not!be!so!badly!ran!to!suggest!inferior!workmanship!
!
Gun!Spit:! ! Surface!must!no!be!so!badly!spit!to!suggest!inferior!workmanship!
!
Dirt:! ! ! Surface!must!no!be!so!badly!dirty!to!suggest!inferior!workmanship!
!
Gloss:! ! ! Can!vary!50%!
!
Cross!Hatch!
Adhesion!Test:! ! 80%!or!better!adhesion!
!
!
Chips:! ! ! No!more!than!4!at!.090”!diameter!in!a!seven!inch!square!
!
Porosity:! ! Not!responsible!for!defects!such!as!degassing!bubbles!and!pitting.!
,
General,Definitions,
,
Scratches! ! A!shallow!groove!or!line!on!the!surface!of!a!part! !
!
Lint! ! ! Fine!strands!of!fiber!covered!by!paint!
!
Dirt,!Dark!Specs! ! Miniscule!particles!embedded!in!the!part!which!show!as!a!color!difference;!They!are!
most!often!sharpZtopped!protrusions!above!the!painted!surface!
Gloss! ! ! A!surface!luster!on!the!finish!or!texture!
!
Flaking,!Peeling! ! Areas!in!which!paint!comes!off!with!light!rubbing;!Very!poor!adhesion!between!
paint!and!part!
!
Chips! ! ! Areas!in!which!paint!ahs!been!knocked!loose!from!the!part!surface!
!
Paint!Runs! ! An!area!of!excess!paint,!which!has!“sagged”!or!flowed!to!a!noticeably!thicker!height!
Gun!Spit! ! Clumps!or!globs!of!paint,!which!are!noticed!above!the!finish!or!texture!
16
!
Work Order Procedure Sheet

Customer: Purchase Order:

Part Name: Lot #
Part #: Date in:
Job # Date Due:
Date Painted:
Oven Temp:
Quantity:
Good Parts:
Pretreatment:
Treatment: SKYCOAT Personnel:______

Paint and Procedures:

Process changes if applicable:

Customer Authorization:
SKYCOAT Authorization:

Set Up Instructions: Batch Test:

Packaging Instructions:

Productions Comments:

Supplier Feedback or discrepant

materials:

Final Inspection (Circle one) Pass Fail Initials:_________

17
TITRATION TEST
ALODINE 5200

Pipet exactly 10 ml of Titrating Solution 15 into a 150 ml

beaker, add 50 ml of DI water, then 5 ml of reagent 44. Take a
30 ml syringe of the Alodine 5200 bath solution; slowly add to
the Titrating Solution until the purple color completely
disappear resulting in a clear or slightly brown solution.
Note: The Titration Solution needs to be swirling as the
Alodine is slowly added.

The concentration may be determined from the table below.

Titration mls Concentration % by volume
27 ……………………………. 1.5 PH 3.1-
20 ……………………………. 2.2 3.5

14.7 ……………………………. 3.0 (Max) Good

10.8 ……………………………. 4.5
9.8 ……………………………. 6.0
7.8 ……………………………. 7.5

The lower number of mls used the higher the concentration

!
!!

18
!

Alodine 5200 Plus Paint Treatment Temperature pH Time % Conc.

1 Spray Rinse
2 Clean Altrex 24 120-130 N/A 5 min. 5
3 Tap Rinse
***1 min.
4 Deoxidine 457 95 Any *** 3
Note: For part adhesion test a
ladder of time.
(variables 30sec.- 5 min.)
5 DI Rinse
6 Alodine 5200 95-105 3-3.6 2 min. 3
Note: If settling of
tank, mix new bath
7 DI Rinse 1 min.
Note: 25 TDS or
Better

1 Powder 200

Alodine 5900 Plus Paint Treatment Temperature pH Time % Conc.

1 Spray Rinse
2 Clean Altrex 24 120-130 N/A 5 min. 5
3 Tap Rinse
***1 min.
4 Deoxidine 457 95 Any *** 3
Note: For part adhesion test a
ladder of time
(variables 30 sec.- 5 min.)
5 DI Rinse
3.5-
6 Alodine 5900 75-110 4.0 5 min. 3
Note: If settling of
tank, mix new bath
Lower pH: sulfuric acid

7 DI Rinse 1 min.
Note: 25 TDS or
Better

19
 Supplier Qualification Form
(This form MUST be completed to be an approved SKYCOAT, LLC supplier)

Name: _______________________________________________________________

Address: _____________________________________________________________

Phone: _______________________________________________________________

Fax: _________________________________________________________________

Website: _____________________________________________________________

Main Contact: _________________________________________________________

Email: _______________________________________________________________

Phone: _______________________________________________________________

Quality Contact: _______________________________________________________

Email: _______________________________________________________________

Phone: _______________________________________________________________

Quality System Certifications

Current Quality Certifications: _____________________________________________

______________________________________________________________________

Future Plans for Quality System: ___________________________________________

______________________________________________________________________

If there are any current quality system certifications, please supply copies of certifications,
quality policy, quality objectives, and quality manual.

Organization Information

Number of Employees:_____________________________________________________

Owner years of experience in this business:_____________________________________

20
Number of years in business:________________________________________________

List of value added services and/or custom items offered:

Financial Information Supplier Response

1. What programs are in place for productivity improvements?

2. What is your Dun and Bradstreet rating?

3. How does our business fit in with your overall business plans?

4. What are your standard payment terms?

Capacity Informationer Response

1. What is your current % of capacity being used?

2. What is the approximate area of your operation?

Quality System Information

1. Is there a controlled and proven effective quality system in place?

2. How do you handle changes from your customers?

3. Do you have a document control process in place? Please explain.

4. Do you have an effective process in place that provides feedback to SKYCOAT on errors and
potential improvements?

5. Do you have a purchasing process in place? Please explain.

6. What is your process to ensure materials purchased are identified, controlled, and tracked?

7. What is the process in place to inform SKYCOAT in the event of issues or late deliveries?

8. How do you ensure safe delivery of products to SKYCOAT?

9. Do you meet all safety and environmental requirements?

10. How do you control non-conforming products?

11. Do you have a corrective and preventive action process in place? Please explain.

21
I certify that the information provided above is true to the best of my knowledge. If there are any
significant changes in the quality system, management, or quality personnel, SKYCOAT, LLC
will be notified within 30 days of those implemented changes.

Supplier Qualification

Name: _______________________________________________________________

Authorized Signature: ___________________________________________________

Date: ________________________________________________________________

SKYCOAT Review and Approval

Observations about Supplier: ______________________________________________

______________________________________________________________________

Approval Status: Approved Not Approved

Name: _______________________________________________________________

Position/Title: _________________________________________________________

Authorized Signature: ___________________________________________________

Date: ________________________________________________________________

Re-Evaluation Summary

Date: ________________________________________________________________

Performed by: _________________________________________________________

Status: _______________________________________________________________

Comments:____________________________________________________________

22
 New Employee Training
Please initial each item as it is completed.

______ Observed work order procedure demonstration according to

job sheet.
Demonstrator Signature:__________________________________
Date:_____________________
______Correctly performed titration using all equipment
including pipettes, beakers, syringes, and required chemicals
Observer Signature:__________________________________
Date:_____________________
______ Read and understand how to complete Work Order Procedure
sheet
______Performed Work Order Procedure correctly on sample
material
Supervisor Signature:__________________________________
Date:_____________________
______ Read and understand Aluminum and Magnesium Conversion
Coating
Treatments
______Read and understand powder preparation guidelines
______Read and understand powder coat applications guidelines
______Performed Work Order Procedure correctly on powder coating
sample material
Supervisor Signature:__________________________________
Date:_____________________
______Read and understand SKYCOAT, LLC Quality Control Manual

Employee signature:_______________________________
Date:_____________________

23
!
Corrective!and!Preventative!Action!Form!
Company!Name:!
Reported!by:!
lot!#:!
Part!#!
Date!product!Received:!
Date!product!Shipped:!
Preventative!or!Corrective!Action:!!
Please!describe!issue:!!

Please!describe!how!this!issue!will!be!prevented/Corrected:!

If!unknown,!please!perform!a!root!cause!analysis!describing:!1.!!The!case!of!the!issue.!2.!!What!is!being!!
done!now!to!fix!the!issue?!!3.!!How!this!issue!will!be!avoided!in!the!future?!

Verification!Notes:!!Include!how!issue!resolution!was!verified!and!date!verified!in!space!below.!

24
!
Maintenance Schedule

Next
Daily Maintenance Procedure Initials Date date
pH meter calibration Standard solution calibration using pH buffers

Weekly Maintenance Procedure

Compressor Check
Air compressor oil
Air lines Air line condenser empty
Air compressor Empty moisture separator compressor
Dehumidifier
DI water filter Check dehumidifier filter (summer)
Check water hardness

Bi Monthly Maintenance Procedure

Air compressor Change compressor oil

Dehumidifier Check dehumidifier filter (winter)

Monthly Maintenance Procedure

Furnace Change furnace filter

Pressure washer Antifreeze in pump when not in use
Engine oil 4-5 hours
Fuel Additive when add fuel

Bi Yearly Maintenance Procedure

Thermometer Calibration Test accuracy
!

25
SKYCOAT, LLC
W6341 HWY 10 Ph. 715-222-9143 email: info@skycoat.com
Ellsworth, WI 54011 Fax. 715-273-5697 www.skycoat.com

Visit us online to learn more about

our products, programs and more.

INDUSTRIAL ARMOR 2013.