Search Results

In this evaluation eight observers viewed small topographical defects in paint samples out of doors and in a mock inspection facility. Each observer rated defect severity and the probability of returning a new vehicle with these defects to the dealer for repair. Severity ratings for defects viewed under the recommended inspection lighting were the same as those made outdoors. A nonlinear model relating the probability of a repair request to defect severity (R2 = .95) is provided. A method of measuring the essential physical attributes of the defect, specular highlight area and modulation, is described. A second model relating defect severity to the essential defect attributes (R2 = .88) is provided.

An improved defect detection system for painted surfaces has been developed which significantly increases topographic defect visibility (dirt-in-paint, sags/runs/drips, sealer-under-paint, spits, craters, etc.) for the final inspector / polisher. These minor defects can then be repaired before leaving the “spillout” deck. A new luminaire was designed to maximize the contribution of several applicable principles. The new process has significantly reduced the number of defects leaving the spillout area, doubled the number of “zero defect” vehicles, and increased energy savings from 25-40%. The improved Paint Inspection Lighting process was issued as a Uniform Process specification by the Ford Motor Company Vehicle Operations and was implemented in all of the Ford North American assembly plants.