QC Engineering Handbook

May 23.2005 Ver.3

SMP Project
Asia Business
Nippon Paint Co., LTD.

1/48
 Contents

(*):additonal item from old version

1. Function of QC Engineering

2. Process Engineering parameters

-Explanation of Process Engineering parmeters
-Examples of PE parameter
-Answer of PE parameter examples

3. Information for Grinding Process

-Grinding Method comparison [Pass vs Cans]
-Grinding mill type
-Grinding Media comparison
-Grinding Media information

4. PWS preparation for good observance

-Outline of PWS preparation for good observance
-PWS preparation (grinding)
-PWS instruction items (grinding)
-Grinding process control
(*ver2) -Grinding media control
-Sample PWS
Pre-mix, Grinding
Let down, filling

5. Examples of useful information for QC Engineering

-Stationary Equipment list
-Portable Equipment list
-Production Capacity
-Cleaning method matrix for grinding mill

6. First Lot Control

(*ver3) -First Lot Control flowchart
-First Lot Control Procedure
-Check points of formula transfer - fm Tech to QCE -
-First Lot Production Preparation Meeting check list

7. Abstract Card
-Explanation of Abstract Card
-Example of Abstract Card

2/48
QC Engineering Function (answer to questions from NPGD)

QC engineering function is very important function like a bridge between technical dept.
and production dept.
1.Main subjects of this function are as follows;
(1)Preparation of PWS (including both for new product and revision/improvement for existing product)
Translate technical formula to production formula, including setting operating conditions such as
grinding parameters.
*preparing PWS for new product is a part of FLC activities.
(2)Implementation of FLC activities
FLC activities include RM-QA, DR activities, pre lab test, PWS preparation, attending production
preparation meeting, first batch making observation, evaluate the result of the first batch including
improvement/countermeasures for the following (2nd) batch, etc.
(3)Reaction to abnormality including customer's complaint
Investigate causes of the problem.
*If the problem is customer's complaint, then need to cooperate with technical dept (S&M dept) to investigate
the causes of the problem. This case, QC engineer need to investigate from the view point from production.
(viewpoint from technical should be investigated by technical dept.)
Sometimes, need to run lab test to confirm reproducibility/repeatability of the problem.
(4)Preparation of AB Card
Through activities mentioned the above, need to prepare technical report especially for any lab test
into AB Card. Then from here, also try to extract information for DR List.
**Our case in NPC, QC engineering group doesn't take care of "application analysis for customer".
(This is technical service matter)

2.Member of QC engineering group

As I mentioned above, QC engineering function includes some part of technical matter,
some part of Quality Control, some part of production.
But this doesn't mean member of this group required the representative from each department.
Much more important thing is that these skill/knowledge (= technical, QC, production) is required
to each member of this group.
In other word, technical matter is taken care by member "A", QC matter is taken care by member "B"
and production matter is taken care by member "C" is not the way to do,　or won't work.
QC engineering should be, member "A" can take care of technical matter, QC matter and production matter.
Also the same with member "B" and "C".
From my experience, without having these skill/knowledge/ability by each member of QC engineering group,
QC engineering function won't work.

3.Evaluation of activities
Especially evaluating the performance of QC engineering function,
if this function is working well, then as a result, probably,
(1)less mis-operation due to inappropriate instruction on PWS
(2)High success ratio of first batch due to FLC activities (including RMQA and DR)
(3)Many AB Cards DR items are generated.
*When I was in QC engineering department, my boss evaluated my performance by how many
AB Cards I prepared, how many DR items I listed.

4.Contents of QC engineering manual/handbook

(1)Equipment information such as
min volume able to mix, min & max volume able to produce, main product currently produced, etc
(whatever useful information for other member)
(2)Check sheet for transferred information
When a new formula is transferred from technical department, what need to be checked, and what are
the viewpoints of checking.
(3)Instruction of QC engineering parameters
Meaning of each parameter, how to get those parameters, etc.
And so on.

3/48
o investigate

4/48
Process Engineering parameters

Grinding condition parameter

1.PC
PC: Pigment Content=Content of pigment in pre-mix formula
PWC: Pigment Weight Content
PVC: Pigment Volume Content
Value of PWC is easy to get compare with PVC.
Normally, PC=PWC (theoretically, PVC is more meaningful )

PC(PWC)= (Total Pigment Weight in pre-mix formula)/(Total Weight of pre-mix formula)

2.VS
VS: Vehicle Solid=Content of solid in total vehicle of pre-mix formula
*exclude pigment from both content of solid and vehicle of pre-mix formula

VS= (Total Solid Content in vehicle of pre-mix formula)/(Total Vehicle weight in pre-mix formula)

3.P/R (R/P) Ratio

P/R: Pigment versus Vehicle Solid ratio in pre-mix formula
*enough/optimum amount of resin for unit amount of pigment

P/R= (Total Pigment Weight in pre-mix formula)/(Solid Weight in vehicle of pre-mix formula)

4.Tip speed (peripheral velocity)

*One of scale-up parameter for condition of dispersion

V=DπR/60
V: tip speed (peripheral velocity) [m/sec]
D: diameter of impeller [m]
R: rotation (revolution) speed [rpm]

5.Residence time
Residence Time: the time/length of one particle of pigment stay inside of a mill during grinding.

RT=Ve*FR
RT: residence time [min]
Ve: volume of mill vessel where mill base is able to exist inside of a mill [L]
FR: flow rate [min/L]

Ve=Vv-Vm-Vd-Vs
Vv: total mill vessel volume [L]
Vm: total true volume of media [L]
Vd: total volume of disks [L]
Vs: volume of rotating shaft [L]

5/48
 Vm=Mw/St
Mw: total weight of media [Kg]
St: true density of media [Kg/L]

Total RT=sum of RT of each pass or turn

6.Grinding time for pass method

GT=Bv*FR/60
GT: grinding time per pass
Bv: pre-mix base (mill base) volume [L]
FR: flow rate [min/L]

Total GT=sum of GT of each pass

7.Number of turn for Circulation (CANS) method

NT=60*Tgt/(Fr*Bv)
NT: number of turn [time]
Tgt: total grinding time [Hr]
Fr: flow rate [min/L]
Bv: pre-mix base (mill base) volume [L]

8.Total grinding time for Circulation (CANS) method

Tgt=Bv*Tnt*FR/60
Tgt: total grinding time [Hr]
Bv: pre-mix base (mill base) volume [L]
Tnt: target number of turn [time]
FR: flow rate [min/L]

6/48
Example

1.Calculation of PWC，VS
example1 example2
Formula Formula by Technical
Material Ratio NV(%) Material Ratio NV(%)
[Pre-mix] Sol a 10
Sol a 2.3 Sol b 15
Sol b 2.3 Resin a 30 60%
Resin a 15 60% Resin b 20 70%
Resin b 10 70% Addtv a 0.5 80%
Addtv a 0.4 80% Addtv b 0.5 50%
Pig a 5 Pig a 5
Pig b 7 Pig b 15
Pig c 8 Total 96

Subtotal 50 PWC=40% VS=50%

Resin for grinding: Resin a
[Let down] Solvent for grinding: Sol a
Sol a 5 Add both additives in pre-mix
Resin a 10 60% Determine formula for grinding (=pre-mix)
Resin c 20 50%

Total 85

Calculate PWC, VS of the above formula

PWC=
VS=

2.Calculation of tip speed (peripheral velocity)

impeller diameter=30cm
shaft frequency=900rpm
tip speed m/s=

3.Calculation of grinding residence time

apparent SG of grinding media＝1.68Kg/L
true SG of grinding media=2.76Kg/L
Mill Vessel volume=100L
filling ratio of grinding media=80% (apparent)
grinding flow rate=30s/L
grinding residence time=

with the above condition

7/48
 -when batch size of pre-mix=1920L : Total grinding time=
-grinding flow rate to get grinding residence time =15min: flow rate (sec/L)=

4.Calculation of number of turn for CANS grinding method

The same condition with item 3 above,
flow rate to get 10 turns and total grinding time=16hours with CANS method,
batch size of pre-mix =1920L
flow rate (L/min)=

The same condition above and when flow rate=15L/min and total grinding
time=16hours then number of turn=

8/48
Example

1.Calculation of PWC，VS
example1 example2 Formula for Production
Formula Formula by Technical Material Ratio
Material Ratio NV(%) Material Ratio NV(%) [Pre-mix]
[Pre-mix] Sol a 10 total pigment=5+15=20 Sol a 4
Sol a 2.3 Sol b 15 PWC=40%=0.4 20/X=0.4 X=50 Resin a 25
Sol b 2.3 Resin a 30 60% X: total amount of pre-mix Addtv a 0.5
Resin a 15 60% Resin b 20 70% Y=50-5-15=30 Addtv b 0.5
Resin b 10 70% Addtv a 0.5 80% Y: total vehicle of pre-mix Pig a 5
Addtv a 0.4 80% Addtv b 0.5 50% VS=50%=0.5 S=30*0.5=15 Pig b 15
Pig a 5 Pig a 5 S: total resin solid in total vehicle of pre-mix subtotal 50
Pig b 7 Pig b 15 S/R=60%=0.6 15/R=0.6 R=25
Pig c 8 Total 96 R: amount of "Resin a" required for pre-mix [Let-down/after-mix]
5+15+25+T=50 T=5 Sol a 6
Subtotal 50 PWC=40% VS=50% T: amount of rest of ingredient for pre-mix Sol b 15
Resin for grinding: Resin a Resin a 5
[Let down] Solvent for grinding: Sol a Resin b 20
Sol a 5 Add both additives in pre-mix Total 96
Resin a 10 60% Determine formula for grinding (=pre-mix)
Resin c 20 50%

Total 85

Calculate PWC, VS of the above formula

PWC=(5+7+8)/50=0.4=40%
VS=(15*0.6+10*0.7)/(50-5-7-8)=16/30=0.533=53.3%
V/P=16/20=0.8

2.Calculation of tip speed (peripheral velocity)

impeller diameter=30cm=0.3m

9/48
 shaft frequency=900rpm
tip speed m/s=0.3*3.14*900/60=14.13[m/sec]

3.Calculation of grinding residence time

apparent SG of grinding media＝1.68Kg/L
true SG of grinding media=2.76Kg/L
Mill Vessel volume=100L
filling ratio of grinding media=80% (apparent)
grinding flow rate=30s/L
grinding residence time=51.3*30/60=25.65min
AV: apparent volume of media in the mill
W: weight of media in the mill
AV=100L*80%=80L W=80*1.68=134.4kg
TV: true volume of media in the mill
V: void volume of the mill
TV=134.4/2.76=48.7L V=100L-48.7L=51.3L

with the above condition

-when batch size of pre-mix=1920L : Total grinding time=1920*30/3600=16Hr
-grinding flow rate to get grinding residence time =15min: flow rate (sec/L)=15*60/51.3=17.5[sec/L]

4.Calculation of number of turn for CANS grinding method

The same condition with item 3 above,
flow rate to get 10 turns and total grinding time=16hours with CANS method,
batch size of pre-mix =1920L
flow rate (L/min)=1920*10/(16*60)=20[L/min]=3[sec/L]

The same condition above and when flow rate=15L/min and total grinding time=16hours
then number of turn=15*16*60/1920=7.5

10/48
Grinding Method Comparison

grinding method
item Pass Circulation [CANS]
mill base viscosity high (75-100KU) low (55-80KU)
required pre-mix time longer than CANS(60min) shorter than Pass(30min)
agitation during grinding better to agitate must agitate
flow rate slow fast
required number of turn N/A >6turns (10turns)
mill pressure low high
particle size distribution narrow broad
required mill type open/closed type closed type
mechanical seal,
required type of shaft seal lip seal, mechanical seal double mechanical seal
easiness of handling relatively hard easy

11/48
Grinding mill type
grouping 1 grouping 2 grouping 3 grouping 4 typical mill
non-media N/A N/A N/A colloid mill
type
roll mill

media type batch N/A N/A ball mill

type
attritor

basket mill

continuous vertical open sand grind mill

type type type
Grain mill

closed Neo Grain mill

type

horizontal closed Dyno mill

type type Super mill
Spike mill
MP mill

12/48
Grinding Media Comparison

media material density price major use [unsuitable] reason of impropriety remark
inexpensive
natrium glass 2.50 [ED paint] Na + ion
(\a/kg)
expensive
special glass 2.74 any product ----- ex. Hi-Bea
(\7~10a/kg)
expensive
zircon 3.85 any product ----- ex. ER120S
(\7~10a/kg)
very expensive
zirconia 6.05 any product -----
(\60~90a/kg)
expensive
steel 7.85 [light color product] contamination
(\7~10a/kg)

13/48
Grinding media information
classification manufacturer/dealer product name particle size (nominal) component SG (tru) hardness
soda-lime PottersBallotini (Toshiba) GB501M 0.84 - 1.19 m/m SiO2 72%
glass Na2O 2.5 Mohs 6.5
K 2O 13.5
GB502M 1.00 - 1.41
CaO 9 (ap.1.5) Vickers 570
GB503M 1.41 - 2.00 MgO 3.5
Al2O3 2
Nippon Fine Particle 0.7 m/m 0.71 - 0.87 m/m SiO2 72.4
Glass / Asada Iron Works 1 0.84 - 1.03 Na2O 13.9 2.5 Mohs 6.5
1 - 1.25 1.03 - 1.27 CaO 8
1.5 1.44 - 1.92 MgO 3.4 Vickers 570
2.0 1.92 - 2.50 Al2O3 0.9
3.0 2.36 - 3.35
special glass Ohara Hi-Bea D24 0.60 - 1.00 m/m SiO2 42-52
/ Morimura Bros.,Inc. Hi-Bea D20 0.80 - 1.20 Al2O3 13-23
Hi-Bea D16 1.10 - 1.50 CaO 10-25 2.74 Mohs 7
Hi-Bea D15 1.30 - 1.70 MgO 6-22
Hi-Bea D11 1.60 - 2.00 others (ap.1.68)
Hi-Bea D10 1.90 - 2.30 TiO2 ZrO2
B2O3
Bright Signage AlphaBeads0.3 0.3 - 0.5 m/m SiO2 55.1
/ Asada Iron Works AlphaBeads0.5 0.5 - 0.8 CaO 22.5
AlphaBeads0.8 0.8 - 1.0 Al2O3 13.5 Mohs 7
AlphaBeads1.0 1.0 - 1.3 B2O3 6.7 2.6
AlphaBeads1.3 1.3 - 1.5 MgO 1.0 Vickers 534
AlphaBeads1.5 1.5 - 1.7 K 2O 0.4
Na2O 0.3
zircon Sepr ER120S 0.6 0.6 - 0.8 m/m ZrO2 68
ER120S 0.8 0.8 - 1.0 SiO2 31 3.8 Mohs 7
ER120S 1.0 1.0 - 1.25 others
ER120S 1.25 1.25 - 1.6 Al2O3 (ap 2.3) Vickers 750
ER120S 1.6 1.6 - 2.0 Fe2O3
ER120S 2.0 2.0 -2.5 TiO2

zirconia /Asada Iron Works 0.5 m/m 0.35 - 0.65 ZrO2 >99
(zirconium 0.8 0.65 - 0.95 SiO2 0.44 6.05 Mohs 8
oxide) 1.0 0.8 - 1.2
1.25 1.05 - 1.45 (ap.3.75) Vickers 1250
1.5 1.3 - 1.7
2.0 1.8 - 2.2

14/48
Preparation of PWS for good observance

1.Assume the facility for preparing PWS

You cannot instruct appropriate operating methods nor operating conditions on a PWS
without assuming the facility to be used, when preparing a PWS.
At least a PWS for the first batch, assume the facility to be used for making the first batch,
and prepare a PWS with appropriate instructions of operating methods/conditions for that facility.
*As long as it can get an expected quality, it is necessary to make an instruction easy for operators
to follow or consider efficiency for production.
*Therefore, whoever prepares PWS should be knowledgeable about process and operations in production.

2.Monitoring ( of the first batch making)

It is important to confirm that whether instructions on a PWS are followed at production,
and easy to observe/operate or not through monitoring first batch making by the person
who prepared the PWS

3.Revision of PWS
As a result of monitoring the first batch making, if there were points which were inappropriate
instructions, able to implement but difficult to observe or gap between instruction and actual result
is too wide, these points are necessary to revise the PWS by the time of making the second batch.

4.Set up multiple PWSs if necessary

If the instructions (including operating condition, etc.) on the PWS are not able to commonize,
(ex. different facility because of different batch size), then prepare (set up) individual PWS
to make suitable instructions for each facility.
*Need to confirm computer system for PWS, whether multiple PWS entry is allowed for one product or not.
*It is necessary for production planning section to select a suitable PWS for the facility
allocated as a production schedule.

15/48
And it is necessary to generate a hard copy of suitable PWS for batch making.

16/48
Grinding

Premix
1)selection of ingredients for premix
-resin
select suitable resins within the formula for grinding (some resins are not suitable for grinding)
If resins not suitable for grinding are used, just after grinding looks OK,
but storage stability might be poor , for example.
-additive
consider purpose of additives
(need to be charged at premix or after-mix for not to ruin an effect of the additive)
-solvent
generally, low flash point solvent is not suitable to add at premix stage

2)cosideration of parameters for premix(=grinding) formula

-PC (Pigment Content)
-VS (Vehicle Solid)
-P/V (V/P) ratio
-premix paste viscosity
(grinding method : pass/circulation)

3)consideration of charging order

-general charging order : resin - solvent - additive - pigment (powder material)

4)consideration of charging condition

-consideration of using extra pot for material difficult to dissolve
-charging material under agitation or without agitation

5)consideration of securement of rinsing solvent

-solubility of rinsing solvent
-amount of rising solvent

6)consideration of method of dissolving microgel

-material for dissolving microgel
-order of charging material for microgel solution

7)consideration of premixing time

-pass method of grinding required longer premix compare with circulation method

8)consideration of compatibility, contamination from the previous batch of equipments

Grinding
1)mill type
-sand grind mill /ball mill / others
-vertical mill / horizontal mill
-open type / closed type

2)grinding method
-pass/circulation

3)media
-type/material
-diameter

17/48
 -charging amount/ratio

4)grinding condition
-flow rate (residence time)
-paste temperature
-cooling water temperature

Let down (after mix)

1)consideration of charging condition
-temperature difference between ground paste and charging material
-charging order
-charging material under agitation or without agitation

18/48
Instruction items on PWS/BT (Grinding)
(ipc=in-process check item)

1.Pre-mixing
1)tank size (volume, diameter/tank #) ---*
2)agitator (HP, type of impeller, diameter of impeller/agitator #) ---*
3)charging (order, speed, under/without agitation, RPM, mixing time, position of impeller, etc.)
4)type and amount of solvent for rinsing tank
5)mixing time/RPM after charging all the ingredients
ipc: viscosity, (S.G.)
*:equipment (tank/agitator) # is enough if it is able to specify the conditions shown above
are fixed by the equipment #.
Instruct the RPM for mixing if mixer has variable speed.

2.Grinding
1)mill type, size/mill #
2)method (pass, # of pass, Cans)
3)media(type, diameter, charging amount)
4)flow rate
5)temperature
6)discharge amount before start grinding
7)type and amount of material to squeeze the mill after grinding
8)with or without agitation during grinding, method
9)method of cleaning mill after grinding (type of solvent, method)
ipc: fineness, viscosity, (S.G.)

3.Let down
1)tank size (volume, diameter/tank #) ---*
2)agitator (HP, type of impeller, diameter of impeller/agitator #) ---*
3)charging (order, speed, under/without agitation, RPM, mixing time, position of impeller, etc.)
4)mixing time/RPM after charging all the ingredients
ipc: viscosity, (S.G.)
*:equipment (tank/agitator) # is enough if it is able to specify the conditions shown above are
fixed by the equipment #.
Instruct the RPM for mixing if mixer has variable speed.

4.Filtration
1)type of filter, size (mesh/microns)

5.Filling/Packing
1)discharge amount before start filling
2)circulation method, root and time before start filling
3)dirt check method before start filling
4)crater check method
5)filling container
19/48
6)filling unit (Kg/L/cc etc.)
7)filling weight
8)indication on label, sticker, lot etc.
9)required sample (retain/inspection/technical/customer/others)
10)container type/size for each sample

20/48
Process control (Grinding process)

1. Premix
1)Fixed formula and operating condition for premix
Especially, be careful about rinsing solvent.
Rinsing solvent should be utilized from the materials in premix formula.
(Premix formula should be fixed including rinsing solvent for premix process)
{material/quantity for rinsing}

2)Premix viscosity
Check the viscosity of mixture at the end of premix process.
Confirm premix viscosity is as usual.
*If not, investigate cause of unusual.

2. Grinding
1)Drain the remained materil inside of the mill.

2)Check the amount of grinding media inside of the mill.

If the amount of media is less than the standard, then add media to
required amount.
{type/diameter of media, charging amount}

3)Initial discharge
Discharge required quantity of initial coming out material from the mill
according to the instruction, if required.
{discharge quantity of first coming out material from the mill}

4)Adjust the flow rate of grinding material to required range.

[Pass method]

21/48
 After adjusting the flow rate, wait for more than residence time of the flow rate,
then check the fineness.
*If you check the fineness too early (less than residence time of the flow rate
after adjusting the flow rate), then you will misjudge the fineness.
If the fineness is not within required range, then adjust the flow rate within the
given/required range of the flow rate.
If you cannot achieve the fineness within the required flow rate range, do not adjust
the flow rate out of required range nor run more than required number of passes
to achieve the required fineness.
[Circulation method]
After adjusting the flow rate to the required range, then grind for required grinding time.
After the required grinding time, check the fineness.
If you cannot achieve the fineness within the required grinding time range, do not
extend the grinding time to achieve the required fineness.

**If you cannot achieve required fineness by required/given operating condition,

then stop the process, and wait for the further instruction.
(Need to investigate the cause why cannot achieve the fineness with given condition)
{grinding method, flow rate, total grinding time (for circulation method), fineness}

5)Check, adjust, record other grinding conditions

Check, adjust and record other grinding conditions which are required.
-Cooling/chilled water temperature (inlet/outlet)
-Load of the mill by ampere meter
-Pressure
-Material temperature (inlet/outlet)
etc.

6)End of the grinding process

Flush the mill paste inside of the mill using the material and quantity according to
the insruction.

22/48
{material/quantity for flush}

23/48
Grinding Media Control

Maintain amount of grinding media is one of important items to be controlled for grinding process.

If you have enough data to determine the additional media and timing for a grinding mill, then you may set a SOP
for media control for a mill according to the data.

If you don't, then following procedure may be one of practical method to control grinding media.

Grinding media control procedure

1.Charge required amount of new media into a mill as an initial charge
Normally, required amount of media is 70-80% of mill volume (apparent)
ex. If the mill volume is 100L, then charge 70L of media.
*need to determine 70% or 75% or 80% as a standard (not between 70% to 80%)

2.Check the level of media inside of the mill

Every batch before grinding, check the level of media inside of the mill.
If the level of media is less than required level, then add media up to required level.

3.Record the quantity of media added

Keep a log of additional quantity of media for each mill.

4.Timing for exchange whole media to new one

When the total additional quantity reached to the same quantity of initial charge for the mill,
then discharge whole media from the mill, and charge required quantity of new media into the mill.

5.Treatment of discharged (used) media

Sieve discharged media at item 4.

24/48
Dispose of small size of media.
Keep media caught on the sieve, and utilize for additional mentioned at item 2.

25/48
 PRODUCT: BLACK DISPERSION S FORMULACDS0005T-01DATE ENT: DATE DUE: BATCH SIZE: 220 GAL INCHARGE:
SEQ NO: LOT NO: OBT #:CDS0005T-01-01 CONTAINER: SIGN: PAGE: 1/1

WEIGH-UP/PRE-MIX/GRINDING/LET-DOWN/BLENDING INSTRUCTIONS EQUIPMENT INFORMATION

% CODE LBS INSTRUCTIONS LOT # INIT SOP# PRE-MIX/LET-DOWN/BLENDING
EQUIPMENT: 10 HP DISSOLVER
USE A 240 GAL POT AS A PREMIX POT. IMPELLER:12" OPERATOR:
USE A 240 GAL POT AS A CATCH POT. DATE/TIME START: END:
THE CATCH POT IS TO BE WEIGHED AND GRINDING
THE WEIGHT IS TO BE RECORDED. EQUIPMENT: 45 L DYNO MILL #9
CATCH POT #: BEAD TYPE: 1.5mm ZIRC BEAD QTY: 36L
CATCH POT WEIGHT: GRINDING LEVE <=10μm GRINDING METHODPASS
TARGET FLOW RATE: 130 - 140 SEC/QT
USE A 10HP DISSOLVER AND 12"IMPELLER OPERATOR: DATE:
FOR PREMIX. WATRWATRPROD PROD
TIME IN OUT IN OUT AMPSPRESFLOWGRIND
*** PRE MIX ***
ADD TO THE PREMIX POT.

2.27 S1511 A 75.4 (SS SOLVENT 1200)

HOLD APROX. 15LBS OF S5650 FOR RINSE

THEN ADD THE REST TO THE POT.

2.27 S5650 B 75.4 (AABBCC SOLVENT)

24.74 L1222 C 821. (R-4ABC)

MIX AT 600 RPM FOR 5 MIN. THEN ADD START:

THE POT UNDER 600 RPM AGITATION. STOP:

0.2 A6666 D 6.64 (DDDDD TCN-02)

0.4 A6688 E 13.3 (DDDDD ZAQ-CHCH)

18.84 A6621 F 625. (DDDDD-TAK)

IN-PROCESS CHECKS/TEST/RANGES
MIX AT 600 RPM FOR 15 MIN. THE ADD START:
THE POT UNDER 600 RPM AGITATION. STOP: *** PRE MIX ***

0.18 P3555 G 5.98 (ZZAA-100) WPG(ACTUAL)/77゜F:

STORMER VISCOSITY(ACTUAL)/77゜F:
10.81 P3535 H 359. (TZCANQ C-100)

5.10 P2899 J 169. (RRTT 4100 P) *** GRINDING ***

STOP AGITATION,SCRAPE AND CHECK THE GRIND <= 10 μm :

LUMPS ON THE WALLS AND BOTTOM OF WPG(9.75 ± 0.20)/77゜F:
THE POT. RINSE THE WALLS OF THE POT STORMER VISCOSITY(68 ± 3 KU)/77゜F:
AND THE SPATULA USING THE S5650 HELD
FOR RINSE.(CHARGE REMAINDER OF THE TOTAL GRINDING TIME:
S5650 HELD FOR RINSE TO THE POT.)
FILLING INSTRUCTIONS/YIELDS
MIX AT 800 RPM FOR 60 MIN. START: PUMP NO: FILTER HOSE NO:
STOP: FILTER SIZE/TYPE:
(64.81) (CDS0005T) 2150.72 *** TOTAL *** DATE: OPERATOR:
TAKE A PINT SAMPLE , MEASURE AND DIRT CHECK: CRATER CHECK:
RECORD PREMIX WPG AND VISCOSITY. REQUIRED ACTUAL WEIGHT/
CONTAINER NET QUANTITY QUANTITY CONTAINER
*** GRINDING ***
DURING GRINDING MIX THE PREMIX POT
USING AN AIR MIXER.(LIGHTNIN ONLY !!!)
THE CATCH POT IS TO BE WEIGHED AND
THE WEIGHT IS TO BE RECORDED.
CATCH POT #:
CATCH POT WEIGHT: PARTIAL WEIGHT: YIELD:
RECORD GRINDING PARAMETERS SAMPLE INFORMATION
PERIODICALLY. RETAIN SAMPLE: 1 QUART
QC SAMPLE: (IN-PROCESS CHECK SAMPLE)
AFTER DISCHARGEING ALL GRIND PASTE TECHNICAL SAMPLEN/A
IN THE CATCH POT MIX FOR 3 MIN USING CUSTOMER SAMPLEN/A
SPATULA, THEN TAKE A 1 QT. SAMPLE FOR PANEL PREPARATION INSTRUCTIONS
IN-PROCESS CHECKS.
MEASURE AND RECORD GRIND, WPG AND
STORMER VISCOSITY.
LEAVE THE SAMPLE IN TECH.LAB.

WEIGH THE GROSS WEIGHT OF THE

CATCH POT CONTAINING GROUND PASTE
AND RECORD THE GROSS WEIGHT AND
NET WEIGHT OF THE GROUND PASTE.

GROSS WEIGHT:
NET WEIGHT:
APPROVALS
26/48
GRAND TOTAL FACTOR=33.2

27/48
 PRODUCT: BLACK PASTE-2 FORMULATS0005T-01DATE ENT: DATE DUE: BATCH SIZE: 220 GAL INCHARGE:
SEQ NO: LOT NO: OBT #: TS0005T-01-07
CONTAINER: SIGN: PAGE: 1/1

WEIGH-UP/PRE-MIX/GRINDING/LET-DOWN/BLENDING INSTRUCTIONS EQUIPMENT INFOMATION

% CODE LBS INSTRUCTIONS LOT # INIT SOP# PRE-MIX/LET-DOWN/BLENDING
EQUIPMENT: 10 HP DISSOLVER
64.81 CDS0005T-0 A ( ) ( BLACK DISPERSION-21) IMPELLER:10" OPERATOR:
DATE/TIME START: END:
CALUCULATE THE AMOUNT OF EACH P-003 GRINDING
INGREDIENT BASED ON THE AMOUNT OF EQUIPMENT:
CDS0005T-01 IN THE LETDOWN POT. BEAD TYPE: BEAD QTY:
GRINDING LEVEL: GRINDING METHOD:
*** LETDOWN *** TARGET FLOW RATE:
OPERATOR: DATE:
14.38L1223 B (R-4DEF) WATRWATRPROD PROD
START 600RPM AGITATION THEN ADD TO THE TIME IN OUT IN OUT AMPSPRESFLOWGRIND
POT.

11.45L5019 C (CABCL 271)

12.49L5018 D (CABCL 225)

4.92L3333 E (EPAAA 8823)

MIX 10 MIN AT 600RPM, THEN ADD TO T START:
POT UNDER AGITATION. STOP:

1.03 A6666 F (SS-52)

MIX 60 MIN AT 1000RPM. START:
WHILE MIXING, GET READY TO MAKE A STOP:
SOLUTION.

*** AZS SOLUTION ***

USE A 55 GAL DRUM AND AN AIR MIXER.

ADD TO THE DRUM.

2.52 S1511 G (SS SOLVENT 1200) IN-PROCESS CHECKS/TEST/RANGES

CHECK THE GRIND OF A6669. IF GRIND IS *** AZS SOLUTION ***
<5μm, ADD TO THE DRUM VERY SLOWLY
UNDER MODERATE AGITATION. GRIND OF A6669 <5μm:
GRIND AFTER S1511+A6669 <5μm:
1.40 A6699 H (AZS-999) GRIND OF AZS SOLUTION <5μm:
STOP AGITATION, CHECK THE GRIND. IF GRIND
IS <5μm THEN ADD TO THE DRUM VERY *** LETDOWN ***
SLOWLY UNDER MODERATE AGITATION.
GRIND AFTER A6666 <10μm:
3.41 L5514 J (U-JUN 22Z-66) GRIND AFTER AZS SOLUTIN <10μm:
MIX FOR 10 MIN.STOP AGITATION AND CHE START:
GRIND OF AZS SOLUTION. STOP: WPG 9.40±0.15/77°F:
STORMER VISCOSITY 65±3KU/77°F:
*** LETDOWN(CONT.) ***
FILLING INSTRUCTIONS/YIELDS
AFTER ADDING A6666 AND MIX FOR 60 MIN, PUMP NO: #8 FILTER HOSE NO#1
CHECK GRIND. IF GRIND IS <10μm AND GRIND FILTER SIZE/TYPE:10MICRONS CUNO
OF AZS SOLUTION IS <5μm, ADD THE AZS DATE: OPERATOR:
SOLUTION TO THE LETDOWN POT VERY DIRT CHECK: CRATER CHECK:
SLOWLY UNDER 600RPM AGITATION. REQUIRED ACTUAL WEIGHT/
MIX FOR 10 MIN, THEN CHECK GRIND. START: CONTAINER NET QUANTITY QUANTITY CONTAINER
IF GRIND IS <10μm ADD TO THE LETDO STOP: EXCLUSIVE RECORD
POT UNDER 600RPM AGITATION. 500GAL TOTE AMOUNT
IN TOTE
1.35 KS0001 K (RRSSTT BB 10% SOLUTION) EXCLUSIVE
55GAL OPEN 430LBS 430 LBS
1.20 KS0002 L (DDBBSS 10% SOLUTION) HEAD DRUM
PARTIAL WEIGHT: YIELD:
1.00 S5650 M (AABBCC SOLVENT) SAMPLE INFORMATION
RETAIN SAMPLE: 1 QUART
MIX FOR 20 MIN AT 600RPM. START: QC SAMPLE: 1 QUART
MEASURE AND RECORD WPG,STORME STOP: TECHNICAL SAMPLEN/A
VISCOSITY. CUSTOMER SAMPLEN/A
119.96 TS0005T-01 *** TOTAL *** PANEL PRIPARATION INSTRUCTIONS

*** FILLING ***

AFTER DISCHARGING INITIAL 2 GAL (APRX.)
IN A PAIL, RECERCULATE FOR 15 MIN THEN
GIVE A QUART SAMPLE FOR DIRT AND
CRATER CHECK.

[FILL IN DRUM]
AFTER QC OK'D THE DIRT CHECK, PROCEED
WITH FILLING.

[FILL IN TOTE]

28/48
 AFTER QC OK'D THE DIRT AND CRATER
CHECK,PROCEED WITH FILLING. APPROVALS

GRAND TOTAL

29/48
[Example of Stationary Equipment List]

EQUIPMENT LIST 5-7-1997

EQUIPMENT # CAPACITY MANUFACTURER LOCATION MAIN USE

D DISSOLVER # 1 10 HP MOREHOUSE-COWLES SMALL BATCH PLANT LET-DOWN,BLENDING

I DISSOLVER # 2 10 HP MOREHOUSE-COWLES 1ST FL W/B PM ROOM PRE MIX

S DISSOLVER # 3 10 HP MOREHOUSE-COWLES 1ST FL S/B PM ROOM PRE MIX

S DISSOLVER # 4 10 HP MOREHOUSE-COWLES 2ND FL BLENDING,LETDOWN

O DISSOLVER # 5 7.5HP MOREHOUSE-COWLES SMALL BATCH PLANT PRE-MIX,LET-DOWN,BLENDING

L DISSOLVER # 6 10 HP MOREHOUSE-COWLES 1ST FL S/B PM ROOM PRE MIX

V DISSOLVER # 7 10 HP MOREHOUSE-COWLES 2ND FL LET-DOWN,BLENDING

E DISSOLVER # 8 10 HP HOCKMEYER 1ST FL LET-DOWN AREA LET-DOWN,BLENDING

R DISSOLVER # 9 50 HP MOREHOUSE-COWLES 2ND FL WITH 1960G LD TANK LET-DOWN

DISSOLVER #10 125 HP+30HP INOUE(HSD) 2ND FL WITH INOUE MIXER PRE-MIX

DISSOLVER #11 20 HP MOREHOUSE-COWLES 2ND FL WITH 790G ST TANK BLENDING

DISSOLVER #12 10 HP HOCKMEYER 1ST FL LET-DOWN AREA LET-DOWN,BLENDING

DISSOLVER #13 10 HP HOCKMEYER 1ST FL LET-DOWN AREA LET-DOWN,BLENDING

DISSOLVER #14 10 HP HOCKMEYER 1ST FL LET-DOWN AREA LET-DOWN,BLENDING

DISSOLVER #15 20 HP ASADA(KONEL) 1ST FL W/B PM ROOM W/B PRE-MIX

DISSOLVER #16 40 HP HOCKMEYER 2ND FL WITH 480G ST TANK BLENDING

DISSOLVER #17 40 HP HOCKMEYER 2ND FL WITH 480G ST TANK BLENDING

DISSOLVER #18 75 HP MYERS 2ND FL WITH 3000G ST TANK LET-DOWN,BLENDING

DISSOLVER #19 40 HP HOCKMEYER 2ND FL WITH 750G ST TANK RECEIVING TANK

M DYNO MILL # 1 25 L CB MILLS 1ST FL S/B AREA S/B RED

I DYNO MILL # 2 20(16.5) L CB MILLS SMALL BATCH PLANT CP-250,BENTONE PASTE

L DYNO MILL # 3 5 L CB MILLS SMALL BATCH PLANT MISCELLANEOUS

L DYNO MILL # 4 25 L CB MILLS 1ST FL S/B AREA S/B YELLOW

DYNO MILL # 5 45 L CB MILLS 1ST FL PRIMER AREA OP-5,BIG BATCH WHITE TINT

DYNO MILL # 6 45 L CB MILLS 1ST FL PRIMER AREA OP-5,BIG BATCH WHITE TINT

DYNO MILL # 7 25 L CB MILLS 1ST FL W/B AREA W/B DARK COLOR TINTS

DYNO MILL # 8 25 L CB MILLS 1ST FL W/B AREA W/B WHITE

DYNO MILL # 9 45 L CB MILLS 1ST FL PRIMER AREA S/B BLACK, DARK COLOR TINTS

S DISSOLVER # 9 1960 GAL MOREHOUSE-COWLES 2ND FL OP-5 LET-DOWN

T DISSOLVER #10 790 GAL INOUE 2ND FL OP-5 PRE-MIX

DISSOLVER #11 790 GAL MOREHOUSE-COWLES 2ND FL BASE COAT

T DISSOLVER #16 480 GAL HOCKMEYER 2ND FL S/B SOLID

A DISSOLVER #17 480 GAL HOCKMEYER 2ND FL S/B CLEAR COAT

N DISSOLVER #18 3000 GAL MYERS 2ND FL BASE COAT

30/48
K DISSOLVER #19 750 GAL HOCKMEYER 2ND FL TBD

31/48
[Example of Portable Equipment List]

PORTABLE POTS
POT NAMED MAX.VOLM STD.VOLM JACKETED/ TARE WT.
NO. SIZE 6" FM TOP 8" FM TOP NON JCKTD WITH LIDS REMARK
1 85G 91GAL 84GAL J FOR KONEL
2 85G 91GAL 84GAL J FOR KONEL
3 160G 146GAL 134GAL NJ
4 160G 146GAL 134GAL NJ
5 160G 146GAL 134GAL J
6 160G 146GAL 134GAL J
7 240G 224GAL 208GAL NJ 626
8 240G 224GAL 208GAL NJ 626
9 240G 224GAL 208GAL NJ 626
10 240G 224GAL 208GAL NJ 626
11 240G 224GAL 208GAL NJ 626
12 240G 224GAL 208GAL J
13 240G 224GAL 208GAL NJ 626
14 240G 224GAL 208GAL J
15 105G 83GAL 78GAL NJ
16 105G 83GAL 78GAL NJ
17 58G 48GAL 45GAL NJ
18 58G 48GAL 45GAL NJ
19 240G 224GAL 208GAL NJ
20 240G 224GAL 208GAL NJ
21 240G 224GAL 208GAL NJ
22 240G 224GAL 208GAL NJ
23 240G 224GAL 208GAL NJ
24 240G 224GAL 208GAL NJ
25 240G 224GAL 208GAL NJ
26 240G 224GAL 208GAL NJ
27 240G 224GAL 208GAL NJ
28 240G 224GAL 208GAL NJ
29 58G 48GAL 45GAL NJ
30 58G 48GAL 45GAL NJ
31 105G 83GAL 78GAL NJ
32 105G 83GAL 78GAL NJ
33 58G 48GAL 45GAL NJ
34 58G 48GAL 45GAL NJ
35 240G 224GAL 208GAL NJ
36 240G 224GAL 208GAL NJ
37 240G 224GAL 208GAL NJ

32/48
38 240G 224GAL 208GAL NJ
39 240G 224GAL 208GAL NJ
40

FILTER PUMP UNITS 5-7-1997

CANISTER NO. OF CHOICE OF PUMP
NO.LENGTH CANISTER CANISTER DRIVE MAIN PRODUCTS
1 LNG/SHT 2 N AIR CLEAR
2 SHORT 2 Y AIR W/B TINT,SOLID
3 SHORT 2 N AIR CP-250,S/B LIGHT COLOR
4 LNG/SHT 2 N AIR W/B WHITE
5
6 LNG/SHT 2 N AIR SOLVENT, THINNER
7
8 LNG/SHT 2 N AIR S/B BLACK,SB5250
9 LNG/SHT 2 N ELECTRIC S/B METALLIC
10 SHORT 2 Y ELECTRIC S/B SOLID
11 N/A N/A ELECTRIC OP-5 PRIMER

33/48
[Example of Production Capacity List]

PRODUCTION CAPACITY
PRODUCT # OF PRODUCTION CAPACITY(G/M)TOTAL
LINE EQUIPMENTS EQIP MAIN PRODUCTS G/BXB/DYXBCH/MNTH CAPACITY

SMALL 7.5HP DISSOLVER 1 CP-250 220G/BX1B/3DX5B/M=1100G 1340G/M

BATCH 16.5L DYNO MILL 1 SB5250 BENTONE PASTE 120G/BX1B/2DX2B/M=240G

5L DYNO MILL 1

10HP DISSOLVER 1

S/B 10HP DISSOLVER 1 OP-5 BLACK PASTE 440G/BX1B/DX15B/M=6600G 7480G/M

BLACK 25L DYNO MILL 1 SB5250 440G/BX1B/3DX2B/M=880G

10HP DISSOLVER 1

S/B 10HP DISSOLVER 1 TINTS FOR SIA 220G/BX1B/3DX7B/M=1540G 1540G/M

TINT 25L DYNO MILL 1

10HP DISSOLVER 1

W/B 20HP KONEL MIXER 1 W/B WHITE TINT 220B/DX1B/3DX7B/M=1540G 3080G/M

TINT 10HP DISSOLVER 1 W/B DARK COLOR TINT 220B/DX1B/3DX7B/M=1540G

25L DYNO MILL 2

10HP DISSOLVER 2

PRIMER 790G HSD 1 OP-5 PRIMER 3000G/BX1B/3DX6B/M=18000 18000G/M

750G RT 1

45L DYNOMIL 3

3000G TT 1

S/B MTLC 790G TANK 1 S/B BASECOAT 700G/BX1B/5DX4B/M=2800G 2800G/M

S/B SOLID 480G TANK 1 S/B SOLID COLOR 450G/BX1B/4DX5B/M=2250G 2250G/M

W/B MTLC 2000G TANK 1 W/B BASE COAT 1960G/BX1B/5DX4B/M=7840G 7840G/M

CLEAR 480G TANK 1 CLEAR 450G/BX1B/3DX7B/M=3150G 3150G/M

SMALL CM 10HP DISSOLVER 1 SMALL BATCH COLOR MTCH 220G/BX1B/5DX4B/M=880G 880G/M

INTM. 10HP DISSOLVER 1 AZS SOLUTION,ETC. N/A N/A

TOTAL 48360G/M

OTHERS FILTER PUMP UNIT 9

240G POT 18 PRDCTION CAPA.

160G POT 4 FINISHED PRODUCT 36900 GAL/MNTH

85G POT 2 INTERMEDIATES 11460 GAL/MNTH

105G POT 2 TOTAL 48360 GAL/MNTH

58G POT 2

34/48
[Example]

Mill #9 (50L Dyno Mill) cleaning method matrix

present

Group c

Group e
Group b

Group d
Group a

Group f
previous

Group a A B B C C D

Group b B A B C D E

Group c B B A C D D

Group d C C C A C C

Group e C D D D A E

Group f E D D C E A

Cleaning method
A: not required (unnecessary)
B: [previous solvent 60kgX10min]+[present solvent 60kgX10min]
C: [previous solvent 60kgX10min]+[present solvent 60kgX10min]Xtwice
D: method "B" + exchange media
E: prohibited

Product group
a:
b:
c:
d:
e:
f:

35/48
First Lot Control Process Flow Chart

Production Prdctn Planning Purchasing QC Engineering / QC Technical Sales & Marketing Customer

Transfer New Formula

Formula change
etc.
Receive
-Formulation sheet
(Formula, QC items
& Spec range, etc.)
-Wet sample
-Sample Data
-Standard Panel
-New RM info
etc.

Design Review
-review transferred
materials
-check DR List
-Pre Lab Test

Take measures for

extracted KY items

RM QA

Extract Q-KY
items

Discuss

N Need to revise Y
Formulation
Sheet

Take measures for

extracted KY items

First Batch Production Preparation Meeting

Take measures for extracted KY items

issue PWS/BT
PWS/BT preparation

First Batch Monitor First Batch

making making

Sampl First Lot Property

e evaluation

First Lot Quality

evaluation
First Lot
productivity
evaluation

QC Check Y
First Lot Product
OK?
Monitor First Lot First Lot
Y,N line trial line trial

First Lot Control First Lot line trial

evaluation evaluation

Need to take
N measures for
next batch?

Take measures for next batch

36/48
 A

The End of First Lot Control

37/48
To : Technical
From :
CC : Sales & Marketing
Date: 11-14-1997

RE : FIRST BATCH CONTROL PROCEDURES

We would like to implement First Batch Control Procedures for both finished products and
intermediates. We suggest that following the systematic approach already in place at the Aichi
Plant (NPC) may be a good strategy.
Key elements of that approach include:

PASSING FORMULA FROM TECHNICAL TO Q.A.

* This should include:
1- Page 1 and Page 2 formulation sheets
2- Actual test results of Lab batch.
3- A 1 quart sample of Lab batch
4- A standard panel
5- Raw Material Control Procedures for any new raw materials.
* Q.A. to review Technical Dept. test results versus formula specifications.
* Q.A. to review formula for Simple Mistakes.
* Q.A. to perform final inspection tests on Lab batch and confirm results versus
Technical Dept. results.
* Q.A. to make Bench Sample and check.
* Q.A. to establish Production Format and in-process check points.
* P.C. to review availability of resources.(especially raw materials and intermediates)

FIRST PRODUCTION BATCH MEETING

(Refer to Appendix 1 for standardized agenda.)
* Items to be discussed and decided upon should include:
1- Description of Product
2- Sales forecast
3- Strong points/ weak points
4- Which items to be included in Q.C. final inspection
5- Which items to be included in Line Trial Report
6- Pre-ship Requirements
7- First batch size and timing
8- Second batch size and timing

PREPARATION FOR MAKING FIRST PRODUCTION BATCH

* Q.A. to issue Original Batch Ticket
* P.C. to re-confirm availability of resources and schedule production.
* P.C. to issue Batch Ticket.
* Production and Q.A. to monitor actual batch making closely and resolve small issues as
they arise.
* Production to issue First Batch Production Report
* Q.A. to perform Final inspection
* Q.A. to start Storage Stability Test

LINE TRIAL AT CUSTOMER'S PLANT

* Sales and Technical Dept. to monitor the result of the first production batch at customer's line
* Sales to issue Line Trial Report

38/48
After this, if everything is OK, then formula is released for Regular Batch Production.
Please share with us your thoughts on this important subject.

c.f.: Definition of the First Batch is not only new products but also include formula change.

39/48
REQUIRED MATERIALS WHEN TRANSFER FORMULATION AS A PRODUCTION BATCH
MATERIALS TO BE OBTAINED
FROM TECH. PRELIMINARY ITEMS TO BE CHECKED OR CONFIRMED BY QC REMARK
1 FORMULATION SHEET (1),(2) a:Check easy or careless mistakes.(ex. miswriting, forget to fill a box, etc.) Do not react by oral information.

b:Is there any particular reason for the procedure shown on "Production Always get official "Formulation Sheet
procedure" box? (1),(2)".
c:Are QC check items , spec range and frequency reasonable? Have any questions or unclear points,
d:Are test methods clear for QC? ask and discuss with Tech.

e: Etc.
2 STANDARD PANEL a:Is the formula of the sample ,which the standard panel was made, the same If not, discuss with Tech. to resolve the
formula with the "Formulation Sheet (1)" ? problems before start batch making.

b:Is the panel making condition ,which standard panel was made, the same with
shown on the "Formulation Sheet"s?
3 STANDARD LAB SAMPLE & a:Is the formula of the standard lab sample the same formula with the a,c,d,e:If not, discuss with Tech. to
EVALUATION RESULT DATA "Formulation Sheet (1)"? resolve the problems(ex.change spec

b:When was the sample made? range etc.) before start batch making.
c:Are all the items on the "Formulation Sheet (2)" tested by Tech. and are the
results all in spec ?
d:Are the test result run by QC using standard lab sample meet the specs shown

on the "Formulation Sheet (2)"?

e:Is the result significantly improved if the case of revision for improvement?
4 REVISION HISTORY SHEET a:Are all the revised items on the "Formulation Sheet"s shown on the "Revision If not, ask Tech. to provide correct

(IF FOR REVISION) History Sheet" ? "Revision History Sheet" or correct

"Formulation sheet"s.
5 PANELS WHICH EVALUATED a:Is the formula of the sample ,which panels were made, the same with the If not, discuss with Tech. to resolve the
STANDARD LAB SAMPLE "Formulation Sheet (1)" ? problems before start batch making.

b:Are the panel making conditions the same with on the "Formulation sheet"s ?

40/48
c:Are the visual evaluation results of the panels match with the data and meet
specs ?

41/48
Production Preparation Meeting Check List Date of Meeting: Filled in by:
Name of Product:
*Mark one of the box for the each item on the right columns whether each item below decided/ need to be
is decided/confirmed and recorded on a copy board at the meeting or not confirmed checked
1. Outline of the product
(1) Who is the customer, where to ship, apply for what
(2) Demand forecast
(3) Schedule after the first trial at the customer (if any)
2. Key points of Quality
(1) Securement of sales/strong points
1) Condition of production process
2) Properties of Quality
(2) Result of line/field trial with the product/sample made by technical (if any)
(3) Weak points and those countermeasures
(4) Confirmation of quality data including color (technical sample, QC pre lab sample)
3.Procurement of Raw Materials
(1) Confirmation of new raw materials. (Internal material codes are determined?)
(2) Raw materials whose consumption changes drastically
(3) Raw materials whose lead time for procurement are long
(4) Confirmation of stock/inventory of raw materials (availability of R.M.)
4.Formula, Standard panel, Standard sample
(1) Date of determination of the formula
Whether product name is agreed with the customer or not (If IU product)
Whether internal product code is determined or not
(2) Is there any difference between transferred formula and sample making formula
If any, what is the reason?
(3) Is standard panel approved by the customer? (If IU product)
(4) When is the date able to obtain the standard panel?
5.Production schedule for the First Batch
(1) The date of formula and other standards transfer from tech to production (QC)
The date of registration to the system and the issuance of the PWS
(2) How much is ordered quantity from the customer? (Confirm order entry)
(3) How much is the minimum quantity for the first batch? (batch size for the 1st batch)
(4) The date of availability of raw materials
(5) The date of start and completion of the first batch
(6) The date of QC inspection and shipment
(7) The date of availability of line/field test result of the first batch
6.Production schedule for the Second Batch
(1) The process/method for the second batch by the shortest process time of the batch
The date of start and completion of the second batch
*start date of the 2nd batch should be immediately after getting the 1st batch result
(2) Batch size for the second batch
7.Actions for Inspection
(1) Whether submission of Certificate of Analysis to the customer is required or not

42/48
 (2) What are the items for COA?
(3) Due date of COA submission to the customer (especially for the first batch)
8.Osolete product
(1) Is there any product become obsolete due to this product?
(2) How to treat stock product which become obsolete?

43/48
AB (Abstract) card

1. Purpose & application

The purpose of preparing AB card is that accumulate all the useful information
obtained through the business activities as company's asset. (not individual asset)

AB card is apply for whatever a report related to technical information.

This information in AB card will be original source of other reports.
ex.: If you need to prepare a report to a customer because of customer's complaint,
probably you will run many experiments to investigate a cause of problem, before
prepare a report to a customer.
If you only prepare a report to a customer, then other useful information only
remains as memoranda or in someone's mind.
To avoid this situation, prepare AB card for each experiment, and use these AB card
as source information when prepare a report to a customer.

2. Viewpoints
How detail you describe on AB card need to be considered.
Some viewpoints are as follows;
1)Even the person him/herself who prepared the AB card will forget the detail what actually
done after 2 - 3 months later.
Prepare AB card detail enough for the person who prepared the AB card can remind later
what actually done.
2)Normally, AB card is reported to the boss of who prepared AB card.
The boss is not familiar in detail as a person in charge.
Prepare AB card detail enough even the boss can comprehend what actually done.
3)If the others want to duplicate the experiment, they need detail procedure/information
for duplication.
Prepare AB card detail enough for others can duplicate the experiment.

44/48
3. Structure
Meaning or what need to be described on each item is as follows;
S Q: Summary & conclusion
Describe summary of the AB card including conclusion.
*Not the title of the AB card.

B P T: Background, situation.
Describe the background/situation why this experiment/investigation etc.
is required/necessary.

H P: Assumption, hypothesis
Describe assumption/hypothesis or strategy of procedure or point of confirmation
through the experiment.

O A&I: Outline of procedure

Describe outline of experiment procedure.

C B&C: Detail conditions of experiment

Describe detail conditions of experiment such as formula, equipments,
operating conditions, etc. (including factor & level)

D D: Criteria
Describe criteria of success/failure of assumption/hypothesis described at "P".
*Tendency of human nature is make judgment success or failure after knowing
the result of the experiment.
But it is important to determine the criteria of success/failure beforehand.

R O: Result/data
Describe the result/data of the experiment.

I Q-O: Consideration
Describe the consideration through the experiment.
ex. Why succeeded/failed.
45/48
 Remained issues.
Strategy/"P" for next experiment. (if the result is not satisfactory)

4. Additional benefit
Logical thinking is essential to technical related activities such as
investigating causes of problem, designing new formula, revising formula, etc.
To prepare AB card will be good training to think matters logically.
*Not only successful result, but also failure result is also important for others
in the future.

46/48
Example of Abstract Card

Q: Using ceramic beads for grinding Nax Acrylic 320#202 Super Black couldn't shorten the grinding
time from current grinding time using glass beads.

P T: To grind Nax Acrylic 320#202 Super Black taking 3-4 passes at production using glass beads
as grinding media.
To improve grinding efficiency, according to the mill manufacture, it is hard to increase
apparent filling ratio of media from 50% (current condition) to 70% with our operating
condition which is not having chiller system.
Need to study the way of improving grinding efficiency by other methods.

P: To confirm whether using ceramic beads as grinding media, with the same apparent filling ratio
with glass beads, is able to improve grinding efficiency or not.

A&I: Using the same with current premix formula of Nax Acrylic 320#202 Super Black,
grind a premix sample with glass beads and ceramic beads individually,
and see whether grinding time by ceramic beads is faster than by glass beads.

B&C: Premix formula Process condition Sample1 Sample2

ingredient weight(g) Premix: Equipment Dispermat Dispermat
ACRYDIC 451.16 Impeller 60mmφ 60mmφ
CA 76.27 speed(rpm) 2000 1000
B-CA 76.27 Grinding: Equipment Dispermat Dispermat
OTSN 4.87 Impeller 60mmφ 60mmφ
RAVEN 22.72 speed(rpm) 2000 2000
M/T 100.62 paste qt(g) 600 600
Total 731.91 media 1.50-2.00mmφglass 1.25-2.00mmφceramic
media qt(g) 600 900

Check premix paste Visc KU/25C and SG/25C

Fineness check: after 20min grinding, then check every 20min until fineness<=10 microns

D: grinding speed to achieve fineness<=10 microns: ceramic media<=80% grinding time of glass beads
47/48
O: Sample1 sample2
Premix Visc KU 76 77
SG 0.95 0.95
Grinding FN/tmp 20min >100 microns/48C >100 microns/40C
40min 80 microns/40C 80 microns/41C
60min 65 microns/42C 65 microns/43C
80min 50 microns/40C 50 microns/43C
100min 40 microns/42C 40 microns/43C
Visc KU N/A N/A
SG N/A N/A

Q-O: There was no difference in grinding speed using glass beads/ceramic beads.
It would appear that viscosity of premix paste is too low to show the difference on grinding
time.
Change the premix formula to increase viscosity of premix paste, then compare the grinding
time with current premix formula whether increasing premix viscosity can shorten the grinding
time than current or not.

48/48