Color measurement of metallic finishes in production: BYK-mac i with smart-process

1. Management of color and effect specifications

For efficient production control, an easy to recognize Pass/Fail indication is a major benefit. Therefore, smart-process offers a comprehensive standard management to define color & effect tolerances.

1.1    Setup of master standards with tolerances

Production specifications can be defined by setting up product families with Pass/Fail limits. If needed even “yellow” warning ranges can be input giving the user enough reaction time before production is out of specification. Customer specific color equations of major automotive makers are already predefined and ensure color control according to their internal specifications.

1.2    Exchange of digital standards for a seamless workflow

Thanks to the outstanding inter-instrument agreement of BYK-mac i “digital standards” can be distributed on a global basis. Color standards can be exported in xml file format and send by email to the entire supply chain, making sure that everybody is using the same target and tolerances.

Figure 1 Definition of digital master with tolerances and limits

2. Definition of standardized measurement procedure

For clear sample identification and menu-guided operation on the instrument, so-called Organizers can be set-up. The entered parameters can be later used for filtering the measurement data in the database. Typical identifiers are model, color and paint line. To define the individual check zones, default or custom specific product schematics can be used. Adjacent check zones can be paired as a “panel match”. The result for the panel match is also displayed in the final Test Report and gives valuable information about color harmony of the complete vehicle in an audit.

Figure 2 Organizer set-up for clear sample identification

3. Test Report for single car analysis

By showing the measurement data for a single test series, this report is ideal for color harmony reviews. For further analysis, the results can be evaluated using different graphs.

3.1    Table with schematic

The product schematic quickly indicates where the “problem areas” are. Single dots represent the Pass/Fail result of the individual check zones, double dots stand for panel matches. The data are also displayed in an easy-to-read data table highlighting the measurements being within warning range or out of specification.

3.2    Scatter graph with history function

The scatter graph shows immediately whether all parts are within specification. Limits for color and effect are indicated by green and red lines. Drilling-in on any data point will display the history of the last 20 readings allowing to recognize trends early and take counteractions.

3.3    Color Travel

Color Travel is the ideal tool to show how individual check zones or colors perform per measurement angle. Charting the color data for all measurement angles per check zone gives an indication of the flop behavior and therefore is an indication for the harmony of the vehicle.

Figure 3 Scatter graph with history function

Figure 4 Color Travel to show flop behavior

4. Weekly overview with Scorecard

This report gives a quick overview how production is running over the selected time range and can be used as a Management Summary Report.

4.1    Definition of data table layout

An easy-to-read data table is showing the average of all selected test series and is highlighting values being within the warning range or out of specification. A pivot function can be used to set-up customized data tables. The layout of these tables can be saved and reloaded later.

4.2    Drill-in function with graphs

If an average is marked “red”, a single click will display the details being single data records. A line graph of the individual measured vehicles including the color & effect limits is shown. The layout of the line graph can be configured to specific needs. Additionally, the data can be charted in a Scatter Graph or as a Color Travel graph.

5. Trend Report over time with comparison function

If a color is out of spec, detailed analysis can be done with the trend report function. Trend report is a typical process control chart showing the measurement data over time (by day, week, month) or by individual. Also here, customized data tables can be defined, saved and reloaded. With the drill in function single data records can be charted in common graphs.

5.1    Comparison of different check zones 

A comparison function allows comparing different check zones, even from different databases. The selected check zones are displayed as different colored lines in Line graph or different colored dots in Scatter plot.
A practical example is comparing adjacent check zones such as fascia vs. body panel to control color harmony.
 

Figure 5 Comparison of two check zones for color harmony review

6. Powerful SQL database and data sharing

In a global world, efficient data sharing between different production sites and among the supply chain is essential. smart-chart uses a powerful SQL database which allows handling of large data sets over a long time period. The database can either be stored locally or recite on a SQL server with defined access rights for the individual users. Extracts of the database (e.g. once per week) can be easily shared between the parties. All reports can be sent to Excel, printed out or sent by email as a PDF file.

7. Summary

Systematic planning and efficient data handling of large data sets is essential to set-up a Global QC Management System. BYK-Gardner’s software smart-chart offers unsurpassed functionality to make you ready for professional BIG DATA management: 

• Powerful standard management with digital master standard distribution
• Predefined customer specific color equations 
• Standardized measurement procedure with organizers
• Powerful SQL database for efficient data handling over a long time period
• Innovative QC reports – Executive Summaries - Trend graphs to monitor process stability

smart-chart has all the tools to make the world of data analysis transparent, easy to interpret and efficient.
Make sure to always have the latest version installed on your computer: https://www.byk-instruments.com/en/software.