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GMW14797

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GMW14797

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WORLDWIDE

ENGINEERING General Specification GMW14797


STANDARDS

Painted Plastic Parts Performance Requirements

1 Introduction
1.1 Scope. This standard covers organic surface coatings on plastic parts and components used for
automotive exterior and interior applications on motor vehicles, and also for painted components within the
engine compartment.
1.2 Mission/Theme. This specification details the performance requirements for applied paints on plastic parts
used for either exterior, interior or engine compartment applications on motor vehicles. This also covers
performance requirements for painted, chrome plated parts. This includes the laboratory test requirements for
GM Approved Paint on Parts (APOPS), Production Part Approval Process (PPAP) approval, processing
conditions, and routine quality control for exterior and interior plastic painted automobile components.
1.2.1 APOPS Approval vs. PPAP Approval. APOPS is intended as detailed review of a new combination of
substrate/paint/paint process for a specific molder/painter. This is accomplished by the GM Materials Engineer
with the supplier. An APOPS approval is documented with either:
i) Entry into either the MATSPC/APOPS database available on GM SupplyPower.
ii) Entry into the APOPS spreadsheet loaded on GM SupplyPower.
iii) Approval document from GM to supplier.
Typically, the molder/painter may re-use the APOPS approval for an additional new part that has the same
substrate/paint/paint process, however, the GM Materials Engineer may request an APOPS submission or
additional testing at their discretion.
For new combinations of substrate/paint/painter, the APOPS data is often used for part (e.g., for exterior parts)
or all (e.g., interior parts) of the PPAP submission. In all cases, the APOPS approval documentation is required
with the PPAP package. Reference PPAP Checklist, Table A15.
1.2.2 Raw Material Approvals. This specification applies only to substrate and paint related materials that
have been qualified and approved to the appropriate GM specifications.
1.2.2.1 Substrates. The substrate must be approved to the appropriate GM material specification. For
previously unpainted substrates, substrate paintability may be demonstrated per GMW16172 (plaques or
parts), or via APOPS testing to the appropriate table:
 Table A1A for exterior applications (including weathering of parts per Table A1A, Note 5)
 Table A1B for exterior applications with paint over chrome (including weathering of parts per Table A1B)
 Table A3 for engine compartment applications
 Table A4 for interior trim applications (including paint over chrome).
1.2.2.2 Paints. GMW3005 requirements must be met for approval to the appropriate, e.g., 998XXXX paint
specification for exterior applications. GM9620M must be met for all new paint colors when applicable, as
specified. GMW14867 must be met for the appropriate, e.g., GMWXXXX paint substrate specific specification
for interior paints.
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1.3 Classification. Not applicable.

2 References
Note: Only the latest approved standards are applicable unless otherwise specified.
2.1 External Standards/Specifications.
ASTM D3763 ISO 105-A02 ISO 6603-2 SAE J1976
ISO/IEC 17025 ISO 2808 ISO 20433 SAE J2527
ISO/TS 16949
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GM WORLDWIDE ENGINEERING STANDARDS GMW14797

2.2 GM Standards/Specifications.
9984260 9984901 GMW3059 GMW14829
9984308 9984904 GMW14124 GMW14867
9984808 9984905 GMW14333 GMW15520
9984810 B 040 0540 GMW14444 GMW15891
9984815 GM4389M GMW14445 GMW15919
9984818 GM9233P GMW14698 GMW16133
9984824 GM9503P GMW14700 GMW16172
9984836 GM9531P GMW14701 GMW16554
9984861 GM9620M GMW14704 GMW16745
9984862 GMW3005 GMW14729 GMW16746
2.3 Additional References. None.

3 Test Preparation and Evaluation


3.1 Resources. Not applicable.
3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a valid
calibration label.
3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measuring
variables as specified in this standard shall be determined correctly with respect to their physical definition.
3.1.3 Facilities.
3.1.3.1 For APOPS Testing. All APOPS testing shall be performed in an accredited laboratory. Laboratory
accreditations to ISO/IEC 17025 are acceptable.
3.1.3.2 For PPAP Testing. Tests performed outside of GM are to use a lab from an organization that is either
third party registered to ISO/TS 16949 or has laboratory accreditations to ISO/IEC 17025.
3.1.3.3 All testing is the responsibility of the GM supplier who applies paint to the parts in question.
3.1.4 Equipment. Not applicable.
3.1.5 Test Vehicle/Test Piece. Not applicable.
3.1.6 Test Time. Not applicable.
3.1.7 Test Required Information. Not applicable.
3.1.8 Personnel/Skills. Not applicable.
3.2 Preparation.
3.2.1 Bake. All bakes must comply with GM Paint approved bake charts for each specific product. GM Paint
approved bake charts are those that have an approval signature of the responsible engineer at the bottom.
These bake charts may be obtained from the paint suppliers.
3.2.1.1 For Exterior Grade Parts. All Thermoplastic Polyolefin (TPO) substrates must be processed using any
of the following three options:
 Option 1: High-bake adhesion promoter + topcoat systems. The adhesion promoter (e.g., 9984808,
9984810, 9984818) is applied wet on wet and co-baked with an approved topcoat high bake system (e.g.,
9984836, 9984861, 9984862) in accordance with the GM Paint approved bake chart.
 Option 2: Low-bake adhesion promoter + topcoat systems. The adhesion promoter (e.g., 9984905) is
applied wet on wet and co-baked with an approved topcoat low bake system (e.g., 9984904, 9984901) in
accordance with the GM Paint approved bake chart.
 Option 3: Flame treated + topcoat systems, low bake or Flame treated + primer + topcoat systems, low
bake. Flame treated (GMW16133) and bake with an approved topcoat (e.g. 9984836, 9984861, 9984862,
9984901, 9984904) or with an approved primer (e.g.; 9984815, 9984824) plus topcoat (e.g.; 9984836,
9984861, 9984862, 9984901, 9984904).
3.2.1.2 Interior paint bake charts are stored in the GM Materials File, MATSPC, or held by the regional
Materials Engineer responsible for interior paint raw material approval.

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March 2012 Page 2 of 30

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3.2.2 Additional Requirements for Exterior.


3.2.2.1 Reprocessing. Defined as running a previously finished part through the Original Equipment
Manufacturer (OEM) process. The reprocessing must agree with the Material Data Sheet and recommendation
from the Paint Material Supplier. The following must be followed at a minimum for all part reprocesses.
3.2.2.1.1 All reprocessed parts must meet all the requirements stated in this specification and all other
specifications and requirements listed on the engineering drawing.
3.2.2.1.2 Sanding to substrate is not allowed. Sanding is allowed on the topcoat system to remove surface
imperfections or defects. Documentation of sanding process is required.
3.2.2.1.3 Clearcoat over Clearcoat and Adhesion Promoter over Adhesion Promoter is not permitted.
3.2.2.1.4 Topcoats and color keyed or color specific primers are to be repaired with the same OEM or two-tone

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color only, specified by the GM color code number, for example WA6502 (i.e., white over white, red over red,
etc.)
3.2.2.1.5 The maximum number of reprocess applications is two for primer and two for topcoat as given in
Table 1.
For GM Europe and GM Holden, multiple coatings are defined for maximum one single over-painting of the
complete paint system. Multiple coatings are not permissible for original equipment parts and parts for after
sales service.
Exception: Multiple coatings for original equipment parts are only permissible, if the coloring is acceptable. No
adverse changes are permissible.

Table 1: Reprocessing Requirements


Maximum Total Film
Number of OEM Maximum Reprocess Maximum Number
Paint Layer Build (of Given Paint
Applications Applications of Bakes
Layer)
Primer 1 2 3 100  (4 mil)
Topcoat 1 2 3 225  (9 mil)
Total 2 4 6 325  (13 mil)

3.2.2.1.6 A part may see a total of six heat cycles in paint and a total of seven heat cycles including post-cure.
3.2.2.1.7 All film builds must meet the minimum requirements specified on the engineering drawing and the
maximum requirements given in Table 2 unless otherwise specified.

Table 2: Maximum Film Builds


Layer Maximum Film Build
Primer 100  (4 mil)
Topcoat 225  (9 mil)

3.2.2.2 Spot repair is not a GM approved process for painted parts (except for sheet molding compound
(SMC)).
3.2.2.2.1 Unless otherwise agreed, SMC must be repaired to meet the requirements in GM9233P.
3.2.3 For Interior Reprocessing. Defined as running a previously finished part through the original (OEM)
process. The reprocessing must agree with the Material Data Sheet and recommendation from the Paint
Material Supplier.
The following must be followed at a minimum for all part reprocesses:
3.2.3.1 The maximum number of reprocess applications is one for primer and one for topcoat.
3.2.3.2 All reprocessed parts must meet all the requirements stated in this specification and all other
specifications and requirements listed on the engineering drawing.

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3.2.3.3 Sanding to substrate is not allowed. Sanding is allowed on the topcoat system to remove surface
imperfections or defects. Documentation of sanding process is required.
3.2.4 For Exterior Components with Paint Over Chrome. Components that are chrome plated and
subsequently painted must be painted with a topcoat system that is approved to either 9984308 or
GMW16554.
3.2.5 For Interior Components with Paint Over Chrome. Components that are chrome plated and
subsequently painted must be painted with a topcoat that is approved to GMW16554 or 9984260, and meets
the requirements of GMW14867 - fogging, oven age at 105 °C, odor, Xenon and sunscreen.
3.3 Conditions.
3.3.1 Environmental Conditions. Not applicable.
3.3.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such
requirements shall be specified on component drawings, test certificates, reports, etc. Tests shall be
conducted using the latest issue of the test procedures indicated.
Unless otherwise specified, painted samples shall be subjected to the testing after a minimum aging period of
72 h following the baking or drying cycle. A shorter aging period may be used, provided it is recognized that
this represents a more severe condition of test and that results obtained at different aging times under 72 h are
not a good basis for comparing the relative performance characteristics of paint finishes.
3.4 Instructions. Figure 1 depicts the APOPS approval process. Parts furnished for APOPS approval shall
meet the test requirements as shown in the appropriate table for the component application.
3.4.1 Component Testing/APOPS - for Painted Exterior, Painted Interior, and Painted Engine
Compartment Components. Component testing is to be performed for the production part per Table A1A for
exterior, Table A1B for exterior components with paint over chrome, Table A3 for engine compartment
components, and Table A4 for interior trim components (including paint over chrome). This testing is required
for APOPS approval. Each molder/painter must have APOPS approval for each combination of
substrate/paint/paint process. Once the molder/painter has APOPS approval for a given combination of
substrate/paint/paint process, this approval may also be used for other components that use the same
combination of substrate/paint/paint process. If any changes are made in the substrate, paint, or paint process,
APOPS testing on components must be repeated and reviewed with the appropriate GM Engineer.
Additionally, PPAP testing must be completed for each unique part.
Note: The APOPS process is not applicable for skinned polyurethane parts. See 4.2.3 on PPAP requirements.
3.4.1.1 All specimens for testing must be obtained from parts that have been molded, painted and processed
using the same equipment, tools, materials, processing conditions and manufacturing locations that will be
used to manufacture production parts for vehicle assembly. If regrind is allowed, all specimens for testing must
be obtained from production parts that are made from the maximum allowable regrind as stated on the
drawing.
3.4.1.2 Each test must be completed on a minimum of three samples, each obtained from separate parts
(except fascias - see 3.4.1.3).
3.4.1.3 For fascia systems, triplicate samples need not be obtained from three separate fascias due to the size
and cost of fascias. In this case, three samples may be taken from different locations on the same part. See
Figure 2 for example of testing locations. Since fascias vary in design, see responsible GM Materials Engineer
if assistance is needed in choosing the locations.
3.4.1.4 For Exterior, testing shall be performed in two colors: White and Light Metallic for original non-repaired
parts. If the color palette contains a Tricoat (such as Bright White Diamond), that color must be tested in
addition to the two standard colors. If the two standard colors are not contained in the color palette, the GM
Materials Engineer may approve substitutions.
3.4.1.4.1 Testing to Table A1A must also be performed on a reprocessed part in White only. For General
Motors North America (GMNA), test on a part that has seen two primer reprocesses and two topcoat
reprocesses (example: primer-bake, primer-bake, primer-bake, topcoat-bake, topcoat-bake, topcoat-bake - six
paint layers). For General Motors Europe (GME) and General Motors Holden (GMH), only one primer
reprocess and one topcoat reprocess is to be tested (primer-bake, topcoat-bake, primer-bake, topcoat-bake -
four paint layers). If white is not contained in the color palette, use the color with the highest film build.
3.4.1.5 For Interior, testing shall be performed in each production color for the application.

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3.4.1.6 All bakes are to be those of the production system and must fall within the GM Paint approved bake
charts for each layer.
3.4.1.7 All coating thicknesses must be in accordance to material requirements as specified on the part
drawing notes or in the math file. All coating thicknesses must be measured and reported.
3.4.1.8 Exterior Parts which are source primed and subsequently top coated at assembly plants shall be
capable of accepting the topcoat paint system and meeting the requirements specified with both prime only
and with both topcoat and prime. See responsible GM Materials Engineer to confirm test requirements for
APOPS on primed parts, and to determine the number of parts to be top coated and to coordinate the top
coating of the parts in the assembly plant.
3.4.1.9 When this testing is completed, the tested specimens cut from the parts and test report will be reviewed
by the responsible GM Materials Engineer and entered into the APOPS database.
Note: Full APOPS approval may be given at this time depending on test results.
3.5 Data. Not applicable.
3.6 Safety. This standard may involve hazardous materials, operations, and equipment. This standard does
not propose to address all the safety problems associated with its use. It is the responsibility of the user of this
standard to establish appropriate safety and health practices and determine the applicability of regulatory
limitations prior to use. Suitable precautions should be taken to ensure that applicable safe limits are not
exceeded when conducting test procedures, processes and/or handling the materials required by this
specification.
3.7 Documentation. Samples of components or material released to this standard shall be tested for
conformity with the requirements of this standard and approved by the responsible GM department prior to the
start of delivery of production level components or materials.
Any change to the component or material, e.g., design, function, properties, manufacturing process and/or
location of manufacture requires a new release of the product.
3.7.1 Changes in Processing. After the initial APOPS has been established, any change in processing
parameters as recorded on Table A6 or A7, Paint Processing Data Form, requires evaluation with the
responsible GM Materials Engineer. It is the sole responsibility of the supplier to provide the customer,
unsolicited, with documentation of any change or modification to the product/process, and to apply for a new
release and/or APOPS approval.
Unless otherwise agreed to, the entire verification test shall be repeated and documented by the supplier prior
to start of delivery of the modified or changed product. In some cases, a shorter test can be agreed to between
the responsible GM department and the supplier.
3.7.2 Test Results. Test reports shall be written per the Requirements for Test Report in ISO/IEC 17025.
Additionally, a test report that contains all of the requirements listed in 3.7.2.1 to 3.7.2.17 shall be submitted to
the GM Materials Engineer (reference Table A14, APOPS Checklist).
3.7.2.1 Table A13, APOPS Request Form; if requested by GM Materials Engineer.
3.7.2.2 A copy of the Registration or Scope of Accreditation for each test facility that provided data.
3.7.2.3 Table A6 or A7, Paint Processing Data Form completed and signed by paint facility management.
3.7.2.4 Table A8, A9 or A10, GM APOPS Test Data Form completed (Table A8 for Exterior, Table A9 for
Interior or Table A10 for Underhood). Enlarge as required. A subset of the tests on this form may be used to
report PPAP data.
3.7.2.5 Copy of material requirements as listed in part drawing notes from the latest print or math file.
3.7.2.6 Signed documentation of the percent regrind on parts tested.
3.7.2.7 Datapaq or equivalent indicating part surface temperature versus time for all paint bakes including
post-cure.
3.7.2.8 Schematic indicating the location of part where Film Build was taken. This includes reprocessed parts.
3.7.2.9 Paint film thickness per ISO 2808 on each part that is used to cut test specimens. Measure a minimum
of four areas on each part; report each measurement. More than four areas may be required due to part
design. See the responsible Materials Engineer for a definition of the number and placement of the areas
required. Report the thickness of each paint layer (i.e., primer, topcoat).
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3.7.2.9.1 For interior and underhood parts, a minimum of three parts in a minimum of three locations per part,
dependent upon part size, shall be measured (if not using a shim). Individual measurement locations will be
indicated with a schematic as well as individual readings and the average of the measurements shall be
reported. (See Note 5 in Table A3 or A4 for details on how to measure film build.)
3.7.2.10 GM9620M Film Build Chart for each coating (if applicable, in accordance with part drawing notes or
math file). (Not applicable for Interior coatings.)
3.7.2.11 A GM approved and signed bake chart for each coating.
3.7.2.12 Schematic indicating the location on the part from which the test plaques were obtained. See Figure 2
for example of a fascia schematic.
3.7.2.13 White parts reprocess twice for reprocess validation. (Not applicable for interior coatings.)
3.7.2.14 Signed documentation of the reprocess procedure used by the painted part supplier.
3.7.2.15 Signed documentation of the sanding process procedure used by the painted part supplier.
3.7.2.16 Tested parts for review by the responsible GM Materials Engineer (see 3.3).
3.7.2.17 All tested samples shall be retained by the supplier for review by the appropriate GM Materials
Engineer at least until APOPS approval is obtained.

4 Requirements and Procedure


4.1 Component Testing/APOPS. (See 3.4.1.) Perform testing on components as indicated in the appropriate
table.
4.2 PPAP Testing. Reference Table A15 – PPAP Checklist.
4.2.1 Exterior Components. Perform testing on all program colors as indicated in Table A5 for components,
unless otherwise noted by the GM Materials Engineer (additional testing/Table A1A or A1B testing may be
required). A printout of the APOPS approval will be required with the PPAP package. If a new part has the
same substrate, paint, paint process, molder and painter as a previous part that is already APOPS approved
(i.e., only geometry is unique), then only Table A5 testing is required for PPAP and a printout of the previous
part’s APOPS approval will be required with the PPAP package.
4.2.2 Interior Components. Perform testing on all program colors as indicated in Table A4 for components,
unless otherwise noted by the GM Materials Engineer (additional testing may be required). A printout of the
APOPS approval will be required with the PPAP package. If a new part has all the same colors, substrate,
paint, paint process, molder and painter as a previous part that is already APOPS approved (i.e., only
geometry is unique), then only Table A12 testing is required for PPAP and a printout of the previous part’s
APOPS approval will be required with the PPAP package. All new colors not previously APOPS reviewed
require Table A4.
4.2.3 Polyurethane Skinned Components. Perform testing as indicated in Table A2 for PPAP. APOPS
approval does not apply.
4.2.4 Engine Compartment Components. Perform testing on all program colors as indicated in Table A3,
unless otherwise noted by the GM Materials Engineer (additional testing may be required). A printout of the
APOPS approval will be required with the PPAP package.
4.3 Daily Quality Control Testing. Testing as stated in this specification, at a minimum, is to be followed
unless otherwise noted by GM Supplier Quality or in the Statement of Requirements. All tests as listed in
Table A11 or Table A12 must be run every shift on one color that is run for that particular shift. Colors must be
randomized. Report the daily test data and date.
A Datapaq or equivalent part temperature chart recorder must be run a minimum of one time per day per oven.
To ensure that each oven is consistent from shift to shift, the Datapaq or equivalent charts must be taken on
alternating shifts. For example: Monday - Shift 1, Tuesday - Shift 2, Wednesday - Shift 1, etc.
4.4 Weekly Quality Control Testing. Testing as stated in this specification, at a minimum, is to be followed
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unless otherwise noted by GM Supplier Quality or in the Statement of Requirements. All tests as listed in Table
A11 or A12 must be run once per week on every color run that particular week. Report the weekly test data
and date.
4.5 Additional Requirements. The following requirements must be met at the specified frequencies. Any
painted part supplier to GM must keep records of the following activities and be able to provide them for review
at any time. No aging period is required for quality control samples. A quality control plan will be developed
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with every supplier for every part to determine the areas of the part in which the tests need to be performed. All
bakes must comply with the GM approved bake charts. Table A11 and A12 have requirements for each quality
control test. OVERALL APOPS PROCESS
New Substrate Material New Paint Material

Example:
- TPO
- Polyester
- SMC Purpose:

Raw Material Testing: To Generically


Performed by
Raw Material &
•Test material properties to Approve New
Paint Suppliers appropriate GMWXXXXX Substrates and
Tested to New Paints.
specification
GMWXXXXX or
998XXXX
•Test paintability of
material per GMW16172
Note: New paint
colors must also
be approved
Raw Material Approvals: through
Performed by Approved Substrates appropriate GM
GM Engineers are entered into Approved Paints
specifications.
MATSPC database are entered into
and marked as MATSPC database
“paintable”

---------------------------------------------------------------------------------------------------------------------------

APOPS Testing: Substrate/Paint Combination is Tested


To be Performed on Production Parts Using Exact
by Part Supplier Production Processing System
(See sections 3.3 & 4.1)
Purpose:

To verify
performance of
substrate/paint
combination
APOPS Approvals: using exact
To be Performed by production
GM Materials
Production-Specific
Source is Approved in process
Engineers
APOPS Database
Note: APOPS
Approval is
required for
PPAP.
Figure 1: Overall APOPS Process
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Figure 2: Fascia Example Location

Figure 3: Initial Adhesion Entire Surface Crosshatch (Exterior)

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5 Provisions for Shipping


5.1 Source Shipment Responsibility. It will be the responsibility of the supplier to insure that the material is
not exposed to temperatures during shipment which would cause the material to fail to meet any of the
requirements of this specification.

6 Rules and Regulations


6.1 Legal Regulations. All materials must satisfy applicable laws, rules, regulations and recommendations
valid in the country of usage.
6.2 Language. In the event of conflict between the English and domestic language, the English language shall
take precedence.
6.3 Inspection and Rejection. Samples of components or materials released to a GM material specification
shall be tested for conformity with the requirements of this material specification and approved by the
responsible Engineering department prior to commencement of delivery of bulk supplies.
A new approval must be received for any changes, e.g., properties, manufacturing process, location of
manufacture, etc. If not otherwise agreed, all testing and documentation normally required for initial release
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must be completed.
It is the responsibility of the supplier to inform the customer in a timely manner, without solicitation, and to
include documentation of all modifications of materials and/or processes and to apply for a new release.
If not otherwise agreed, all release tests shall be repeated and documented by the supplier prior to
commencement of delivery of non-conforming bulk supplies. In individual cases, a shorter test can be agreed
to between the responsible Engineering department and the supplier.
6.4 Initial Source Approval. No shipments shall be made by any supplier until representative initial production
samples have been approved by the appropriate Materials Engineering department(s) as meeting the
requirements of this specification.
6.5 Material Safety Data Sheets/Safety Data Sheets (MSDS/SDS). For new product submissions, or when a
change in chemical composition of an existing product has occurred, a complete copy of the Material Safety
Data Sheet/Safety Data Sheet must be submitted in compliance with the Globally Harmonized System of
Classification and Labeling of Chemicals (GHS) requirements or other country-specific MSDS/SDS
requirements. In addition, product MSDS/SDS submissions must be in compliance with specific country
General Motors TMC003 Material Safety Data Sheet/Safety Data Sheet guidance documents where available.
6.6 All materials supplied to this standard must comply with the requirements of GMW3059, Restricted and
Reportable Substances for Parts.
6.7 Certificate of Analysis. The supplier shall be responsible for submitting a Certificate of Analysis with each
batch of material arriving at a plant. This document shall be prepared and provide data in accordance with the
requirements detailed in GM4389M.
6.8 Parts for Aftersales Service. Parts for aftersales service shall be primed. Completely coated Parts for
aftersales service shall fulfill the requirements to GMW14797.

7 Approved Sources
Engineering qualifications of an approved source are required for this standard. Only sources listed in the GM
Materials File MATSPC under this standard number have been qualified by Engineering as meeting the
requirements of this standard.

8 Notes
8.1 Glossary.
MATSPC: Global repository of GM approved materials for corresponding GM Engineering Standards.
PGC: Perceived gloss of 2 (Low Gloss) when measured at 60 degrees gloss on flat, ungrained samples.
Reprocessing: Running a previously finished part through the original equipment manufacturer (OEM)
process.

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8.2 Acronyms, Abbreviations, and Symbols.


APOPS Approved Paint on Parts
DRE Design Release Engineer
DUNS Dun and Bradstreet
GHS Globally Harmonized System of Classification and Labeling of Chemicals
GME General Motors Europe
GMH General Motors Holden
GMNA General Motors North America
L/D Ratio of Screw Length/Diameter
MAI Multi-axial Impact
mil Thousandths of an inch
MSDS Material Safety Data Sheet
OEM Original Equipment Manufacturer
PGC Perceived gloss of 2 (Low Gloss) (see Glossary 8.1 for definition)
PMETS Paint Materials Engineering Technical Specialist
PPAP Production Part Approval Process
PUR Polyurethane
RIM Reaction Injection Molding
SDS Safety Data Sheet
SLE Supplier Liaison Engineer
SMC Sheet Molding Compound
SPEC Specification
TPO Thermoplastic Polyolefin

9 Coding System
This standard shall be referenced in other documents, drawings, etc., as follows:
GMW14797

10 Release and Revisions


This standard was originated in November 2005. It was first approved by the Materials Engineering Group in
November 2006. It was first published in April 2007.
Issue Publication Date Description (Organization)
1 APR 2007 Initial publication.
2 OCT 2009 Major changes to entire document. (Global Materials and Corrosion Team)
3 MAR 2012 Added requirements for paint over chrome for exterior components; revisions
to interior and underhood requirements. (Finishes and Coatings Global
Subsystem Leadership Team)

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Appendix A

Table A1A: APOPS Requirements for Exterior Painted Parts (White, White Repair, Light Metallic)
Test Class GM Specification Requirements
Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Note 1
Adequacy of Cure GMW15891 Maximum rating of 0 for systems with
clearcoat.
Maximum rating of 1 for monocoats.
96 h Humidity followed by GMW14729/ No Appearance Change
Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
240 h Humidity followed by GMW14729/ No Appearance Change
Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Chip Resistance GMW14700 Minimum rating of 9.
(Method (A or B) and C)
Mandrel Bend – Flex 23 °C GM9503P Minimum rating of 8. Flexible Substrates
Note 2
(GMW16746) Only (< 800 MPa Flexural Modulus)

Gasoline Resistance-Dip GMW14333-A Rating 2. No color change or paint removal to


Note 3
previous surface or lifting or peeling of paint
film. No Appearance Change.
Gasoline Resistance- GMW14333-B Maximum paint removal of 20% after
--````,`,`,`,,`,,``,,,`-`-``,```,,,`---

Immersion - Test to 15, 30, 15 minutes immersion. Report results after


45 and 60 minutes. 30, 45 and 60 minutes immersion.
(TPO Substrates Only)
Chemical Resistance (not GMW14701 All materials rated 10 except as follows:
required if paint is approved Rating 8 - Egg Albumin, Acid Rain
to a GM 998XXXX pH 3 and 4, Tap Water, Sulfuric Acid pH 4.
specification)
Rating 6 - Sulfuric Acid pH 0 and 2.
Rating 4 - Brake Fluid.
Moisture Cold – Cycle A GMW14124 No Appearance Change.
+24 h Humidity GMW14729 No Appearance Change.
+Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Multiaxial Impact, at 0 °C ASTM D3763 All ductile failures.
and 2.2 m/s (For Fascias
Only)
Multiaxial Impact, at 0 °C ISO 6603-2 Report results.
(For Fascias Only) – Speed:
4.4 m/s
Probe: 20 mm diameter
Clamp: 40 mm diameter

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Test Class GM Specification Requirements


2
Water Jet (For Fascias GM9531P-B Maximum paint removal of 60 mm .
Only) (GMW16745-B)
Thermal Shock (For TPO GMW15919 No removal.
Substrates Only)
Note 4
Resistance to Cleaning See No Appearance Change. At hairline, peelings
Equipment of total width 1 mm permissible.
Film Build ISO 2808 Minimum of four readings.
Note 5
Weather Resistance See -
Weathering Visual inspection and gloss Equal to original untested sample.
+ Appearance measurement

Weathering GMW14829 Maximum rating of 1.


+ Tape Adhesion Crosshatch
Weathering GMW14729 No Appearance Change.
+ 96 h Humidity followed by GMW14829 Maximum rating of 1.
Tape Adhesion
--````,`,`,`,,`,,``,,,`-`-``,```,,,`---

Crosshatch
Note 1: Contact responsible GM Engineer to determine required solvent.
Note 2: Cold temperature Mandrel Bend testing per GM9503P (GMW16746) if suffix M2 is specified on drawing (for example:
GMW14797-M2).
Note 3: Gasoline Resistance-Dip testing per GMW14333-A if suffix GD is specified on drawing (for example: GMW14797-GD).
Note 4: Resistance to Cleaning Equipment. Before the test, cut a straight hairline with a length of 5 to15 cm (or appropriate to the size of
the test piece) to the base material of the test piece with a sharp knife or any other suitable instrument. The test piece is submitted to the
high pressure hot water jet of a commercial deconservation facility for 30 ± 5 s. The distance between the surface of the test piece and the
nozzle shall be 25 cm ± 5 cm. The temperature of the water shall not exceed +80 °C ± 3 °C, pressure 8 MPa ± 5 MPa.
Note 5: Weather Resistance - Only required if paintability testing per GMW16172 has not been completed for the substrate. If required,
test to one of the following:
 SAE J1976-A, 12 months exposure in Miami, FL area
 SAE J2527-A Extended UV Filters, 2500 kJ/m2 exposure to exterior Xenon arc Weatherometer.

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Table A1B: APOPS Requirements for Exterior Parts with Paint Over Chrome
Test Class GM Specification Requirements
Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Note 1
Adequacy of Cure GMW15891 Maximum rating of 0 for systems with clearcoat.
Maximum rating of 1 for monocoats.
96 h Humidity followed by GMW14729/ No Appearance Change
Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
240 h Humidity followed GMW14729/ No Appearance Change
by Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Chip Resistance GMW14700 Minimum rating of 7.
(Method (A or B) and C)
Gasoline Resistance-Dip GMW14333-A Rating 2. No color change or paint removal to
Note 2
previous surface or lifting or peeling of paint film. No
Appearance Change.
Chemical Resistance (not GMW14701 All materials rated 10 except as follows:
required if paint is Rating 8 - Egg Albumin, Acid Rain pH 3 and 4, Tap
approved to a GM Water, Sulfuric Acid pH 4.
998XXXX specification)
Rating 6 - Sulfuric Acid pH 0 and 2.
Rating 4 - Brake Fluid.
Moisture Cold - Cycle A GMW14124 No Appearance Change.
+24 h Humidity GMW14729 No Appearance Change.
+Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
2.
Water Jet GM9531P-B Maximum paint removal of 60 mm
(GMW16745-B)
Thermal Shock GMW15919 No removal.
Note 3
Resistance to Cleaning See No Appearance Change. At hairline, peelings of total
Equipment width 1 mm permissible.
Film Build ISO 2808 Minimum of four readings.
Oven Age - 168 h at
83 °C GMW14700 Minimum rating of 7.
+ Chip Resistance (Method (A or B) and C)
Weather Resistance SAE J2527-A Extended
2
UV Filters, 2500 kJ/m
exposure to exterior
Xenon arc
Weatherometer.
Weathering Visual inspection and Equal to original untested sample.
+ Appearance gloss measurement

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Test Class GM Specification Requirements


Weathering GMW14829 Maximum rating of 1.
+ Tape Adhesion Crosshatch
Weathering GMW14729 No Appearance Change, No Blistering.
+ 96 h Humidity followed GMW14829 Maximum rating of 1.
by Tape Adhesion Crosshatch
Weathering GMW14700
+Chip Resistance (Method (A or B) and C) Minimum rating of 6.
Weathering GMW15919 No removal.
+Thermal Shock
Note 1: Contact responsible GM Engineer to determine required solvent.
Note 2: Gasoline Resistance-Dip testing per GMW14333-A if suffix GD is specified on drawing (for example: GMW14797-GD).
Note 3: Resistance to Cleaning Equipment. Before the test, cut a straight hairline with a length of 5 to15 cm (or appropriate to the size of
the test piece) to the base material of the test piece with a sharp knife or any other suitable instrument. The test piece is submitted to the
high pressure hot water jet of a commercial deconservation facility for 30 ± 5 s. The distance between the surface of the test piece and the
nozzle shall be 25 ± 5 cm. The temperature of the water shall not exceed +80 ± 3 °C, pressure 8 ± 5 MPa.

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Table A2: PPAP Requirements for Skinned Polyurethane Foam Exterior Parts
Test Class GM Specification Requirements
Note 1
Tape Adhesion (x-scribe) See No removal on cut edges or peeling of film. In
multi-coat systems, no peeling of individual layers.
Note 2
Adequacy of Cure GMW15891 Maximum rating of 0 for systems with clearcoat.
Maximum rating of 1 for monocoats.
144 h Humidity followed GMW14729 No Appearance Change. No removal on cut edges or
by Tape Adhesion Note 1
See peeling of film. In multi-coat systems, no peeling of
individual layers.
Note 3
Chip Resistance - GMW14700 Minimum rating of 9.
(Method A or B and C)
Gasoline Resistance-Dip GMW14333-A Rating 2. No color change or paint removal to previous
surface or lifting or peeling of paint film. No
Appearance Change.
Moisture Cold - Cycle A GMW14124 No Appearance Change.
+ 24 h Humidity GMW14729 No Appearance Change.
+Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Resistance to Cleaning Note 4
See No Appearance Change. At hairline, peelings of total
Equipment width 1 mm permissible.
Weather Resistance Note 5
See
+ Appearance Visual inspection and Equal to original untested sample.
gloss measurement
Note 1: Before testing adhesion, an X shall be scribed through the finish to the substrate with a sharp knife or other suitable instrument. A
strip of adhesive tape (B 040 0540) shall be adhered to the finished surface using hand pressure and ensuring freedom from creases, air
bubbles, etc. The tape shall cover the full width of the scribed X. Subsequently, the tape shall be rapidly (but not jerked) pulled off by hand.
Note 2: Contact responsible GM Engineer to determine required solvent.
Note 3: Only for parts in the area of stone impact.
Note 4: Resistance to Cleaning Equipment. Before the test, cut a straight hairline with a length of 5 to15 cm (or appropriate to the size of
the test piece) to the base material of the test piece with a sharp knife or any other suitable instrument. The test piece is submitted to the
high pressure hot water jet of a commercial deconservation facility for 30 ± 5 s. The distance between the surface of the test piece and the
--````,`,`,`,,`,,``,,,`-`-``,```,,,`---

nozzle shall be 25 ± 5 cm. The temperature of the water shall not exceed +80 ± 3 °C, pressure 8 ± 5 MPa.
Note 5: SAE J2527-A, Extended Filter, 2500 KJ/m2 exposure to exterior Xenon arc Weatherometer

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Table A3: APOPS and PPAP Requirements for Engine Compartment Components
Test Class GM Specification Requirements
Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Note 1
Adequacy of Cure GMW15891 Maximum rating of 0 for systems with clearcoat.
Maximum rating of 1 for monocoats.
72 h Humidity followed by GMW14729, Option No Appearance Change.
Tape Adhesion A or B Maximum rating of 1.
GMW14829
Crosshatch
240 h Humidity GMW14729 No Appearance Change.
Gasoline Resistance-Dip GMW14333-A Rating 2. No color change or paint removal to
previous surface or lifting or peeling of paint film.
No Appearance Change.
Moisture Cold - Cycle A + 24 h GMW14124 No Appearance Change.
Humidity GMW14729 No Appearance Change.
+Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Resistance to Cleaning Note 2
See No Appearance Change. At hairline, peelings of
Equipment total width 1 mm permissible.
Note 3
Film Thickness ISO 2808 Method 3A, Per engineering drawing/math file.
minimum of 3

--````,`,`,`,,`,,``,,,`-`-``,```,,,`---
measurements per part,
report average as well
as individual readings.
Heat Resistance E ≤ 3.0
Note 4
168 h at 120 °C , no change in appearance/gloss/color
after visual inspection.
+72 h Humidity GMW14729 No Appearance Change.

+Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Note 1: Contact responsible GM Engineer to determine required solvent.
Note 2: Resistance to Cleaning Equipment. Before the test, cut a straight hairline with a length of 5 to15 cm (or appropriate to the size of
the test piece) to the base material of the test piece with a sharp knife or any other suitable instrument. The test piece is submitted to the
high pressure hot water jet of a commercial deconservation facility for 30 ± 5 s. The distance between the surface of the test piece and the
nozzle shall be 25 ± 5 cm. The temperature of the water shall not exceed +80 ± 3 °C, pressure 8 ± 5 MPa.
Note 3: If Method 3A (shim) is not used and film build measurements are taken using microscopy (Method 5A), then film build samples
should be taken from the flattest point farthest from an edge in the main appearance surface area. For grained samples, measure 1 peak
and 1 valley in a single location on a part and record each measurement and average. Repeat 3 times per part. Measure 1 part per color.
Report all layers individually.
Note 4: CIELAB color space, 10 degree observer, illuminant D65, specular included, sphere geometry, before and after exposure.

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Table A4: APOPS and PPAP Requirements for Interior Trim Components
Note 1 Note 1
Test Test Procedure Requirement
Cure GMW14867, Cure paragraph No paint film degradation when viewed at
Note 2
10 X magnification.
Note 3
Adhesion GMW14829, Crosshatch ≥ 95% paint retention, Rating 1.
Humidity/Adhesion GMW14867, Humidity paragraph (144 h No evidence of blistering, water spotting or
GMW14729, option A or B, GMW14829 gloss change; ≥ 95% paint retention,
Crosshatch) Rating 1.
Oven GMW14867, Oven Aging paragraph No color or gloss change, loss of adhesion,
Note 4
Age/Adhesion (GMW14729, GMW14829 Crosshatch) distortion or exudation; ≥ 95% paint
retention, Rating 1.
Sunscreen and GMW14445 and GMW14698, 1 mm Rating ≤ 2 and no penetration of the painted
Insect Repellent hemispherical tip, 8 N load surface when evaluated with and without
Note 5
Resistance Test 10 X magnification.
Impact Resistance GMW15520, Multi-axial Instrumented No more than 20% reduction in mean impact
Note 6
Impact Test paragraph energy and sample break behavior must not
(ASTM D3763 or ISO 6603-2, -30 °C) change from ductile to brittle.
Film Thickness ISO 2808 Method 3A, minimum of Per engineering drawing/math file or, if not
Note 7
3 measurements per part, report average specified, the default values for film build are
as well as individual readings. as follows: 1.0 ± 0.2 mil, 25 ± 5 m for hard
touch paints or 2.0 ± 0.2 mil, 50 ± 5 m for
soft touch and semi soft touch paints.
Scratch and Mar GMW14698, 1 mm hemispherical tip, No noticeable marring, whitening or
Note 8 Note 9
Resistance - as 13 N load penetration of the painted surface.
received and After Scratch requirement: No visible penetration.
Oven Aging Mar requirement: No obvious visually
apparent marring.
Resistance to GMW14867, Effects of Cleaners Rating of ≥ 4.
Cleaning agents paragraph (ISO 20433, ISO 105-A02)
Note 1: Test Procedure details and Requirement details are documented in GMW14867. Additional evaluation descriptions are included in
the referenced Notes in this document for clarity. In the event of disagreement with the verbiage in this table and GMW14867, GMW14867
details supercede these. When part size or shape makes the above testing prohibitive, testing may be done on plaques painted in the
production process provided the reviewing program Materials Engineer grants written permission for such.
Note 2: Evaluation of the crock cloth is not required. Slight gloss increase of the paint film for low gloss (PGC) surfaces is acceptable.
Examples of degradation of the paint film include wrinkling, perforation or removal.
Note 3: Brittleness of the paint film, as evidenced by chipping or flaking while scribing the test lines shall be cause for rejection.
Note 4: The required part exposure temperature defined in GMW14444 may be substituted if agreed to by the program materials
engineer.
Note 5: Examples of unacceptable change (rating > 2) are blisters, perforation, cracking or removal of any kind. In the absence of any of
these negative visual reactions after testing at 8 N, a slight gloss change and slightly visible scribe line (mar) is acceptable and considered
to be a rating ≤ 2. The reviewing program Materials Engineer in conjunction with (as appropriate) the regional Materials Engineer
responsible for interior paint raw material approval has the final authority to determine the disposition of a sunscreen result for grained
parts.
Note 6: Multi-axial Impact (MAI) is for painted deployable surfaces only or at the program Materials Engineer’s request. Test only
materials capable of ductile break behavior at -30 °C or lower. Multi-axial impact testing is done on plaques and need not be repeated for
each submission of the same substrate, same paint, same process. Reference of successful data presented in previous APOPS
combinations is acceptable. MAI is for APOPS only and is not required for PPAP submissions. A note must be added in the Remarks
section of the APOPS entry in MATSPC indicating whether or not impact testing was submitted and reviewed.
Note 7: If Method 3A (shim) is not used and film build measurements are taken using microscopy (Method 5A), then film build samples
should be taken from the flattest point farthest from an edge in the main appearance surface area. For grained samples, measure 1 peak
and 1 valley in a single location on a part and record each measurement and average. Repeat 3 times per part. Measure 1 part per color.
Report all layers individually.
Note 8: If 13 N produces substrate tearing or gouging, test unpainted part to 10 N, 8 N, 5 N and 2 N to find the greatest load that produces
no tearing or gouging. Test the painted part to that reduced load. Stretching of the paint film is acceptable.
Note 9: Metallic coatings may falsely appear to have penetration of the coating due to the orientation of the mica or aluminum flake.
Evaluation of metallic paints should be done with 10 X magnification to confirm the initial observations. Slight gloss increase of the paint
film for low gloss (PGC) surfaces is acceptable.

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Table A5: PPAP Testing Matrix for Exterior Plastic Painted Parts (Including Paint Over Chrome
Note 1
Applications) - All Program Colors
Test Class GM Spec Requirements
Tape Adhesion GMW14829 Maximum rating of 1.
Crosshatch
Note 2
Adequacy of Cure GMW15891 Maximum rating of 0 for systems
with clearcoat.
Maximum rating of 1 for monocoats.
96 h Humidity followed by Tape Adhesion GMW14729 No appearance change.
GMW14829 Maximum rating of 1.
Crosshatch
240 h Humidity followed by Tape Adhesion GMW14729 No Appearance Change.
GMW14829 Maximum rating of 1.
Crosshatch
Chip Resistance GMW14700 Minimum rating of 9.
(Method A or B
and C)
Water Immersion followed by Tape Adhesion GMW14704 2 h minimum.
GMW14829 Maximum rating of 1.
Crosshatch
Mandrel Bend - Flex 23C - 4T Flexible GM9503P Minimum rating of 8 (Flexible substrates
Note 3
Substrates Only (GMW16746) < 800 MPa Flexural Modulus).
Note 4
Gasoline Resistance - Dip GMW14333 No color change or paint removal to
(Method A) previous surface or lifting or peeling of
paint film. No Appearance Change.
Multiaxial Impact at 0 °C and 2.2 m/s ASTM D3763 All ductile failures.
Note 3
(For Fascias Only - )
Multiaxial Impact, at 0 °C ISO 6603-2 Report results.
Note 5
(For Fascias Only - )
Speed: 4.4 m/s
Probe: 20 mm diameter
Clamp: 40 mm diameter
2
GM9531P-B Maximum paint removal of 60 mm .
--````,`,`,`,,`,,``,,,`-`-``,```,,,`---

Water Jet (For Fascias Only)


(GMW16745-B)
Note 6
Initial Adhesion - Entire Surface GMW14829 Maximum rating of 1 per tape pull.
See Figure 3. Crosshatch
Film Build ISO 2808 Minimum of four readings.
Note 1: This table outlines the test requirements on production parts for PPAP approval on all program colors. In addition to these tests,
APOPS approval must also be demonstrated prior to PPAP. See sections 3.4 and 4.2.1.
Note 2: Contact responsible GM Engineer to determine required solvent.
Note 3: Cold temperature Mandrel Bend testing per GM9503P (GMW16746) if suffix M2 is specified on drawing (for example:
GMW14797-M2).
Note 4: Gasoline Resistance-Dip testing per GMW14333-A if suffix GD is specified on drawing (for example: GMW14797-GD).
Note 5: Must be done for each fascia geometry (front, rear, up-level, base, etc.) on reprocessed part (painted three times) only in white or
color with highest film build.
Note 6: Test one part of each geometry, any one color, once production spray pattern is established. See Figure 3.

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Table A6: Exterior Paint Processing Data Sheet


Exterior Painted Parts - Paint Processing Data Sheet
Enter applicable data, complete certification statement at end of table, and submit with test report.
Vehicle Usage In Mold Coating (SMC)? (yes/no) _________________
Vehicle Name ______________________________ Supplier ____________________________________
Model Year ________________________________ Product Code _______________________________
Part Description Approved to GM Spec ________________________
Part Name _________________________________ Film Thickness ______ microns
Part Number _______________________________ Cure Time __________________________________
Part Molding Cavity Number ___________________ Mold Temperature ______ °C
Plastic Compound Solvent Wipe:
Supplier ___________________________________ Solvent ____________________________________
Product Code ______________________________ Dilution ____________________________________
Approved to GM Specification _________________ Destat Blow Off? ______________________________
Regrind Power Wash? ________________________________
Maximum percent to be used in production _________ Power Wash Chemical Supplier _________________
Is plastic compound precolored? (yes/no) _____________ Power Wash Information:
(If no, then complete the following three sections) Stage Function Product Sec Conc Temp psi μOHM
Color Concentrate Code ºC
Color concentrate Supplier ____________________
Product Code ______________________________
Color Concentrate Carrier Resin _______________
Let down ratio (resin: concentrate) ______________
Color concentrate weight percent of total color
concentrate produce added ____________________
Carrier Resin weight percent of total color
concentrate produce added ____________________ Other? ______________________________________
Color Concentrate Blender Equipment
Color Meter Type ____________________________ Adhesion Promoter
Mixing Bin Size ______________________________ Supplier ____________________________________
Weight System ______________________________ Product Code _______________________________
System to monitor weight ratio of resin to color Approved to GM Specification __________________
concentrate _______________________________ Line Speed _________________________________
Safety controls if out of spec range for ratio ______ Batch number _______________________________
Screw Design Reducing Solvent ____________________________
Compression ratio (L/D, 24:1 and up required) _____ Reduction (See Note 1) ______%
Company that manufactured the screw ___________ Viscosity ___________________________________
Type/name of screw __________________________ Number of Wet Coats _________________________
Molding Location Flash Time Between Wet Coats ______minutes
Company __________________________________ Flash Time After Last Wet Coat ______minutes
DUNS Number ______________________________ Baking or Drying Condition (See Note 2)
Contact Name _______________________________ Part Surface Temperature ______°C
Contact Number _____________________________ Time At or Above Indicated Temp ______minutes
Location ___________________________________ DATAPAQ Recording (yes/no) ______________
Date Molded ________________________________ Dry Film Thickness (See Note 3) ______ microns
Painting Location
Company __________________________________ Primer
DUNS Number ______________________________ Supplier ____________________________________
Contact Name _______________________________ Product Code _______________________________
Contact Number _____________________________ Approved to GM Specification __________________
Location ___________________________________ Line Speed _________________________________
Date Printed ________________________________ Batch number _______________________________
Surface Preparation (prior to painting) Reducing Solvent ____________________________
Post–Cure (For RIM)? (yes/no) _________________ Reduction (See Note 1) ______ %
Oven Type ________________________________ Viscosity ___________________________________
Bake Time at Surface Temp ______ °C Number of Wet Coats _________________________
Part Surface Temperature ______ °C Flash Time Between Wet Coats ______minutes
Flame Treatment? (yes/no) _____________________ Flash Time After Last Wet Coat ______minutes
Equipment/Controller Type ___________________ Baking or Drying Condition (See Note 2)
Distance to Part ____________________________ Part Surface Temperature ______ °C
Flame Travel Speed ________________________ Time At or Above Indicated Temp ______minutes
Flame Treat Verification Method _______________ DATAPAQ Recording Required
Dry Film Thickness (See Note 3) ______microns

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Table A6: Exterior Paint Processing Data Form – Continued


Line Speed _________________________________
Second Power Wash? Batch number _______________________________
Power Wash Chemical Supplier _________________ Reducing Solvent ____________________________
Power Wash Information: Reduction (See Note 1) ______%
Stage Function Product Sec Conc Temp psi μOHM Viscosity ___________________________________
Code ºC Number of Wet Coats _________________________
Flash Time Between Wet Coats ______minutes
Flash Time After Last Wet Coat ______minutes
Baking or Drying Condition (See Note 2)
Part Surface Temperature ______°C
Time At or Above Indicated Temp ______minutes
DATAPAQ Recording (yes/no) _______________
Dry Film Thickness (See Note 3) ______microns
Top Coat
Supplier ____________________________________ Description of Spray Equipment: __________________
Product Code _______________________________
Approved to GM Specification __________________ Description of Baking Ovens (Gas fired, electric air
Color Base Coat _____________________________ circulating, IR, etc.): ____________________________
Line Speed _________________________________
Batch number _______________________________ For Adhesion Promoter
Reducing Solvent ____________________________ ____________________________________________
Reduction (See Note 1) ______%
Viscosity ___________________________________ For Primer
--````,`,`,`,,`,,``,,,`-`-``,```,,,`---

Number of Wet Coats _________________________ ____________________________________________


Flash Time Between Wet Coats ______minutes
Flash Time After Last Wet Coat ______minutes For Topcoat
Dry Film Thickness (See Note 3) ______microns ____________________________________________

Clear Coat Cure check solvent (for final topcoat)


Supplier ____________________________________ ____________________________________________
Product Code _______________________________
Approved to GM Specification __________________

Note 1: Calculate reduction as follows: Percent Reduction = [(Volume of paint after reduction – Volume of paint
before reduction)/(Volume of paint before reduction)] X 100

Note 2: Submit graphic recording of part surface temperature as a function of time in baking oven.

Note 3: Report measured dry film thickness. Reference ISO 2808. Please include a film build “mapping” of every
part style.

Certification Statement

I certify that the Paint Processing Data is complete and accurate.

Signature _____________________________________________ Date _______________________________


Name ______________________________________________ Title ________________________________
Company _____________________________________________ Telephone ___________________________
Address __________________________________________________________________________________

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Table A7: Interior and Underhood Paint Processing Data Form


Interior Painted Parts - Paint Processing Data Sheet
Enter applicable data, complete certification statement at end of table, and submit with test report.
Vehicle Usage Paint Supplier ________________________________
Vehicle Name ______________________________ Paint System (Adh Pro/base/clear, as appropriate):
Model Year ________________________________ ____________________________________________
Part Description Approved to GM Specification: ___________________
Part Name _________________________________
Part Number _______________________________ Description of Spray Equipment: __________________
Part Molding Cavity Number ___________________ (robot, manual…)
Mold Release_______________________________
Plastic Compound Adhesion Promotor/Primer Layer
Supplier ___________________________________ Batch number ________________________________
Product Code ______________________________ Reducing Solvent ____________________________
Approved to GM Specification _________________ Reduction (See Note 1) ______________________%
Molding Location Viscosity ___________________________________
Company __________________________________ Flash Time After Last Wet Coat __________minutes
DUNS Number ______________________________ Flash Temp __________ °C
Contact Name _______________________________ Cure time_______________ minutes
Contact Number _____________________________ Cure temp__________ °C (See Note 2)
Location ___________________________________ Cure type (Gas fired, electric air circulating, IR, etc):
Date Molded ________________________________ ___________________________________________
Painting Location
Company __________________________________ Single Layer Processes
DUNS Number ______________________________ Batch number ________________________________
Contact Name _______________________________ Reducing Solvent ____________________________
Contact Number _____________________________ Reduction (See Note 1) ______________________%
Location ___________________________________ Viscosity ___________________________________
Date Painted ________________________________ Flash Time After Last Wet Coat __________minutes
Flash Temp __________ °C
Surface Preparation (prior to painting) Cure time_______________ minutes
Flame Treatment? (yes/no) _____________________ Cure temp__________ °C (See Note 2)
Equipment/Controller Type ___________________ Cure type (Gas fired, electric air circulating, IR, etc):
Distance to Part ____________________________ ___________________________________________
Flame Travel Speed ________________________
Flame Treat Verification Method _______________ Multi-Layer Processes (Lasered and Base/Clear)
In Mold Coating (PUR)? (yes/no) _________________ Color 1
Supplier ____________________________________ Batch number ________________________________
Product Code _______________________________ Reducing Solvent ____________________________
Approved to GM Spec ________________________ Reduction (See Note 1) ______________________%
Mold Release_______________________________ Viscosity ___________________________________
Cure Time __________________________________ Flash Time After Last Wet Coat __________minutes
Mold Temperature ________ °C Flash Temp __________ °C
Solvent Wipe: Cure time_______________ minutes (or wet-on-wet)
Solvent ____________________________________ Cure temp__________ °C (or wet-on-wet) (See Note 2)
Dilution ____________________________________ Cure type (Gas fired, electric air circulating, IR, etc):
Destat Blow Off? ______________________________ ___________________________________________
Power Wash? ________________________________
Power Wash Chemical Supplier _________________ Color 2
Power Wash Information: Batch number ________________________________
Stage Function Product Sec Conc Temp psi μOHM Reducing Solvent ____________________________
Code ºC Reduction (See Note 1) ______________________%
Viscosity ___________________________________
Flash Time After Last Wet Coat __________minutes
Flash Temp __________ °C
Cure time_______________ minutes (or wet-on-wet)
Cure temp__________ °C (or wet-on-wet) (See Note 2)
Cure type (Gas fired, electric air circulating, IR, etc):
___________________________________________
Other? ______________________________________

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Table A7: Interior and Underhood Paint Processing Data Form - Continued

Color 3
Batch number ________________________________ Cure temp__________ °C (See Note 2)
Reducing Solvent ____________________________ Cure type (Gas fired, electric air circulating, IR, etc):
Reduction (See Note 1) ______________________% ___________________________________________
Viscosity ___________________________________
Flash Time After Last Wet Coat __________minutes
Flash Temp __________ °C
Cure time_______________ minutes

Note 1: Calculate reduction as follows: Percent Reduction = [(Volume of paint after reduction – Volume of paint
before reduction)/(Volume of paint before reduction)] X 100

Note 2: Submit graphic recording of part surface temperature as a function of time in baking oven (e.g. Datapaq) and
paint supplier’s bake chart.

Certification Statement

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I certify that the Paint Processing Data is complete and accurate.

Signature _____________________________________________ Date _______________________________


Name ______________________________________________ Title ________________________________
Company _____________________________________________ Telephone ___________________________
Address __________________________________________________________________________________
Email _____________________________________________

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GM WORLDWIDE ENGINEERING STANDARDS GMW14797

Table A8: GM APOPS Exterior Test Data Form


COMPANY NAME:
REPORT #

RESULTS - TRIPLICATE SAMPLES PER COLOR


TEST GM SPEC REQUIREMENTS WHITE LIGHT METALLIC WHITE REPAIR TRICOAT
COLOR NAME_______ COLOR NAME_______ COLOR NAME_______ COLOR NAME_______
WA#_________ WA#_________ WA#_________ WA#_________
TAPE ADHESION GMW14829 MAX RATING OF 1
ADEQUACY OF CURE GMW15891 MAX RATING OF 0 FOR
CLEAR; MAX RATING 1 FOR
MONOCOATS.
96 HR HUMIDITY GMW14729 NO APPEARANCE CHANGE
+ TAPE ADHESION GMW14829 MAX RATING OF 1
240 HR HUMIDITY GMW14729 NO APPEARANCE CHANGE
+ TAPE ADHESION GMW14829 MAX RATING OF 1
CHIP RESISTANCE - A or B GMW14700 MIN RATING OF GM 9 (7
FOR PAINT OVER CHROME)
CHIP RESISTANCE - C GMW14700 MIN RATING OF GM 9.
MANDREL BEND-FLEX 23oC-4T GM9503-P MIN. RATING OF 8
*FLEXIBLE SUBSTRATES ONLY (GMW16746) (FLEXIBLE SUBSTRATES)
GASOLINE RESISTANCE-DIP GMW14333-A RATING 2. NO COLOR
CHANGE, NO PAINT
REMOVAL OR PEELING, NO
APPEARANCE CHANGE.
GASOLINE RESISTANCE-IMMERSION GMW14333-B MAX PAINT REMOVAL OF
15 MIN. 20% AFTER 15 MIN.;
30 MIN. REPORT RESULTS AFTER
45 MIN. 30, 45 AND 60 MIN.
60 MIN.
CHEMICAL RESISTANCE GMW14701 SEE TABLE A1 OR A2
MOISTURE COLD-CYCLE A GMW14124 NO APPEARANCE CHANGE
+ 24 HR HUMIDITY GMW14729 NO APPEARANCE CHANGE
+ TAPE ADHESION GMW14829 MAX RATING OF 1
MULTIAXIAL IMPACT ASTM D3763 ALL DUCTILE FAILURES
ISO6603-2 REPORT RESULTS
WATER JET GM9531P-B MAX PAINT REMOVAL OF
(GMW16745-B) 60mm2
THERMAL SHOCK GMW15919 NO REMOVAL
RESISTANCE TO CLEANING EQUIPMENT SEE TABLE NO APPEARANCE CHANGE.
A1 OR A2 AT HAIRLINE, PEELINGS OF
TOTAL WIDTH 1MM
--````,`,`,`,,`,,``,,,`-`-``,```,,,`---

PERMISSIBLE.
WEATHER RESISTANCE SEE TABLE
A1 OR A2
+ APPEARANCE VISUAL/ EQUAL TO CONTROL
GLOSS
+ TAPE ADHESION GMW14829 MAX RATING OF 1
+ 96 HR HUMIDITY FOLLOWED BY TAPE GMW14729/ NO APPEARANCE CHANGE.
ADHESION GMW14829 MAX RATING OF 1
+ CHIP RESISTANCE (FOR PAINT OVER GMW14700 MIN RATING OF GM 6
CHROME APPLICATIONS)
+ THERMAL SHOCK (FOR PAINT OVER GMW15919 NO REMOVAL
CHROME APPLICATIONS)
OVEN AGE (FOR PAINT OVER CHROME 168 HOURS AT
APPLICATIONS) 83°C
+CHIP RESISTANCE (FOR PAINT OVER GMW14700 MIN RATING OF GM 7
CHROME APPLICATIONS) - A OR B
+CHIP RESISTANCE (FOR PAINT OVER GMW14700 MIN RATING OF GM 7
CHROME APPLICATIONS) - C
MEASURED FILM BUILDS:
ADHESION PROMOTER
PRIMER
BASE COAT / COLOR COAT
CLEARCOAT

PART NAME: PART NUMBER:

LABORATORY: PHONE:
COMPANY/GM DIV., AND ADDRESS

TESTED BY: DATE:


PRINT NAME & SIGN
E-MAIL ADDRESS:

© Copyright 2012 General Motors Company All Rights Reserved

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Table A9: GM APOPS Interior Test Data Form


RESIN COMPANY NAME: RESIN:

PAINT COMPANY: PAINT:

RESULTS - TRIPLICATE SAMPLES PER COLOR


Paint Color 1: Paint Color 2: Paint Color 3: Paint Color 4:
Substrate Color: Substrate Color: Substrate Color: Substrate Color:
TEST GM SPEC REQUIREMENTS* Colorant Source: Colorant Source: Colorant Source: Colorant Source:
NO PAINT FILM
DEGRADATION WHEN
GMW14867, CURE VIEWED AT 10X
CURE PARAGRAPH MAGNIFICATION
ADHESION MINIMUM 95% PAINT
RETENTION, RATING 1
GMW14829
144 HR HUMIDITY NO EVIDENCE OF
BLISTERING, WATER
SPOTTING OR GLOSS
GMW14729 CHANGE
+ ADHESION MINIMUM 95% PAINT
RETENTION, RATING 1
GMW14829
168 HR OVEN AGE GMW14867, OVEN NO COLOR OR GLOSS
AGING CHANGE, LOSS OF
PARAGRAPH, ADHESION, DISTORTION
GMW14729 OR EXUDATION
+ ADHESION MINIMUM 95% PAINT
GMW14829 RETENTION, RATING 1
SUNSCREEN AND INSECT MAXIMUM RATING 2 AND
REPELLENT RESISTANCE + NO PENETRATION OF THE
SCRATCHING PAINTED SURFACE WHEN
EVALUATED WITH AND
GMW14445 + WITHOUT 10X
GMW14698 MAGNIFICATION
IMPACT RESISTANCE -30oC NO MORE THAN 20%
GMW15520, REDUCTION IN MEAN TO
MULTIAXIAL IMPACT ENERGY AND
INSTRUMENTED SAMPLE BEHAVIOR MUST
IMPACT TEST NOT CHANGE FROM
PARAGRAPH DUCTILE TO BRITTLE
FILM THICKNESS ISO 2808 METHOD PER ENGINEERING
3A, MINIMUM OF 3 DRAWING/MATH FILE OR,
MEASUREMENTS IF NOT SPECIFIED, THE
PER PART, DEFAULT VALUES FOR
REPORT FILM BUILD ARE AS
AVERAGE AS FOLLOWS: 25±5 MICRONS
WELL AS (1.0±0.2 MIL) FOR HARD
INDIVIDUAL TOUCH PAINTS OR 50±5
READINGS MICRONS (2.0±0.2 MIL)
FOR SOFT TOUCH AND
SEMI SOFT TOUCH PAINTS.
SCRATCH & MAR RESISTANCE NO NOTICEABLE MARRING,
WHITENING OR
PENETRATION OF THE
PAINTED SURFACE
SCRATCH REQUIREMENT:
NO VISIBLE PENETRATION.
MAR REQUIREMENT: NO
GMW14698, 1 MM OBVIOUS VISUALLY
HEMISPHERICAL APPARENT MARRING.
TIP, 13N LOAD
AS RECEIVED
PER ABOVE PER ABOVE
AFTER OVEN AGING

PER ABOVE PER ABOVE


RESISTANCE TO CLEANING AGENTS
GMW14867,
EFFECTS OF
CLEANERS RATING GREATER THAN
PARAGRAPH OR EQUAL TO 4

*NOTE: SEE APPLICABLE REQUIREMENT NOTATATION IN "APOPS AND PPAP REQUIREMENTS FOR INTERIOR TRIM COMPONENTS" TABLE.
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PART NAME: PART NUMBER:

LABORATORY: PHONE:
COMPANY/GM DIV., AND ADDRESS

TESTED BY: DATE:


PRINT NAME & SIGN

EMAIL ADDRESS: REPORT:

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Table A10: GM APOPS Underhood Test Data Form


RESIN COMPANY NAME: RESIN:
PAINT COMPANY: PAINT:

RESULTS - TRIPLICATE SAMPLES PER COLOR


TEST GM SPEC REQUIREMENTS Paint Color 1: Paint Color 2: Paint Color 3: Paint Color 4:
Substrate Color: Substrate Color: Substrate Color: Substrate Color:
TAPE ADHESION GMW14829 MINIMUM 95% PAINT
RETENTION, RATING 1 MAX
ADEQUACY OF CURE GMW15891 MAX RATING OF 0 FOR
CLEAR; MAX RATING 1 FOR
MONOCOATS.
72 HR HUMIDITY GMW14729 NO APPEARANCE CHANGE
+ TAPE ADHESION GMW14829 CROSS MAX RATING OF 1
HATCH
240 HR HUMIDITY GMW14729 NO APPEARANCE CHANGE
GASOLINE RESISTANCE-DIP GMW14333-A RATING 2. NO COLOR
CHANGE, NO PAINT
REMOVAL OR PEELING, NO
APPEARANCE CHANGE.
MOISTURE COLD-CYCLE A GMW14124 NO APPEARANCE CHANGE
+ 24 HR HUMIDITY GMW14729 NO APPEARANCE CHANGE
+ TAPE ADHESION GMW14829 CROSS MAX RATING OF 1
HATCH
RESISTANCE TO CLEANING SEE TABLE A4 NO APPEARANCE CHANGE.
EQUIPMENT AT HAIRLINE, PEELINGS OF
TOTAL WIDTH 1MM
PERMISSIBLE.
FILM THICKNESS ISO 2808 METHOD PER ENGINEERING
3A, MINIMUM OF 3 DRAWING/MATH FILE.
MEASUREMENTS
PER PART, REPORT
AVERAGE AS WELL
AS INDIVIDUAL
READINGS.
HEAT RESISTANCE 168 HOURS AT 120°C E ? 3.0, NO CHANGE IN
APPEARANCE, GLOSS, OR
COLOR
+ 24 HR HUMIDITY GMW14729 NO APPEARANCE CHANGE.

+ TAPE ADHESION GMW14829 CROSS MAX RATING OF 1


HATCH

PART NAME: PART NUMBER:

LABORATORY: PHONE:
COMPANY/GM DIV., AND ADDRESS

TESTED BY: DATE:


PRINT NAME & SIGN
E-MAIL ADDRESS:

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Table A11: Exterior Quality Control Testing

Test Class GM Spec Requirements Daily Testing Weekly Testing


Tape Adhesion GMW14829 Maximum rating of 1. X X
Note 1
Adequacy of Cure GMW15891 Maximum rating of X X
0 for systems
with clearcoat.
Maximum rating of
1 for monocoats.
96 h Humidity followed by Tape GMW14729 No appearance X
Adhesion GMW14829 change.
Maximum rating of 1.
Water Immersion followed by GMW14704 2 h minimum - No X X
Tape Adhesion GMW14829 paint removal.
Crosshatch Maximum rating of 1.

Mandrel Bend - Flex 23 °C. Test GM9503P Minimum rating of 8 X


at cold temperatures if on (GMW16746) (flexible substrates
drawing. < 800 MPa).
Gasoline Resistance - Dip Test GMW14333-A No color change or X
if on drawing. paint removal to
previous surface or
lifting or peeling of
paint film. No
appearance change.
Film Build ISO 2808 Minimum of four X X
readings.
Note 1: Contact responsible GM Engineer to determine required solvent.

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Table A12: Interior Quality Control Testing


Daily Weekly
Test Test Procedure Requirement
Testing Testing
Cure GMW14867, Cure paragraph No paint film degradation X X
when viewed at 10 X
Note 1
magnification.
Adhesion GMW14829 ≥ 95% paint retention, X X
Note 2
Rating 1.
Humidity/ GMW14867, Humidity No evidence of blistering, X
Adhesion paragraph (144 h GMW14729, water spotting or gloss
option A or B, GMW14829 change; ≥ 95% paint retention,
Crosshatch) Rating 1.

Film Thickness ISO 2808 Method 3B, Per engineering drawing or, if X X
Note 3
minimum of 3 measurements not specified, default to be
per part, report average as 1.0 ± 0.2 mil, 25 ± 5 m for
well as individual readings hard touch paints or
2.0 ± 0.2 mil, 50 ± 10 m for
soft touch paints.
Note 1: Evaluation of the crock cloth is not required. Slight gloss increase of the paint film for low gloss (PGC) surfaces is acceptable.
Examples of degradation of the paint film include wrinkling, perforation or removal.
Note 2: Brittleness of the paint film, as evidenced by chipping or flaking while scribing the test lines shall be cause for rejection.
Note 3: If Method 3A (shim) is not used and film build measurements are taken using microscopy (Method 5A), then film build samples
should be taken from the flattest point farthest from an edge in the main appearance surface area. For grained samples, measure 1 peak
and 1 valley in a single location on a part and record each measurement and average. Repeat 3 times per part. Measure 1 part per color.
Report all layers individually.

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Table A13: APOPS Request Form (To be Completed if Requested by GM Engineer)


APOPS Request Form Date:

If requested by GM Materials Engineer, this APOPs Request Form is to be completed by the Part Supplier for
authorization prior to APOPs testing. Procedure to complete APOPs Request Form;
1. Contact responsible GM Material Engineer on the proposed change and for the required GM stakeholders to be contacted.
2. List the required GM stakeholders (as required by Material Engineer) in Table #2.
3. Complete form and send to GM stake holders listed in Table #2.
4. Have the GM stakeholder listed in Table #2 indicate support status and sign.

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5. Send completed (signed_ document to the Materials Engineer for approval. Follow up meeting with stakeholders as needed.

Requestor Name: Job Title (technical position reqd):


Phone #: Fax #: Email:
Vehicle Program: Company Name:
Part # (less finish): Part Name:
Date supplier plans to implement proposed system into production:

Table #1 Current and Proposed System


Current System Proposed System
APOPS #
Substrate (GM Spec #)
Substrate Supplier
Substrate Product Code
Flame Treatment
Powerwash Supplier Code
Powerwash Supplier Name
Powerwash Cleaner Product Code
Powerwash Rinse Aid Product Code
Primer / AdPro (GM Spec #)
Primer / AdPro Supplier Name
Primer / AdPro Product Code
Basecoat / Clearcoat (GM Spec #)
Supplier Name Base Coat / Clear Coat
Product Code Base Coat / Clear Coat
Molder Name / Location
Painter Name / Location
Other:

Reason for the change? Cost Savings Improved Quality Explain :

Is there a change in paint processing ? No ______ Yes ______ Explain:________________________________


If cost savings, did you as a supplier send supporting documentation to the GM buyer? Yes ______ No ______
If a quality improvement did you, as a supplier, send supporting data from a certified facility to the GM Materials
Engineer and other GM personnel as directed by the GM Material Engineer? Yes No

Table #2 GM Stakeholders Contacted


Check if GM Signature of GM Stakeholder and
GM Stakeholder Stakeholder
GM Department Telephone Number Contact
Required to be Date indicate
contacted Support or Not Support

Materials Engineer
Paint PMETS
Paint SLE
DRE
Supplier Quality Eng
Buyer
The proposed APOPs Request Form was reviewed by the responsible GM Materials Engineer, ________________, authorizing
the supplier to conduct APOPs testing for submission. A signed APOPs Reqeust Form is required with the APOPs submission
package.

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Table A14: APOPS Checklist

 Table A13 – APOPS Request Form; if requested by GM Materials Engineer


 Table A6 or A7 – Paint Processing Data Form completed and signed by paint facility management
 Table A8, A9 or A10 – GM APOPS Test Data Form completed and signed
 Copy of completed lab report, if requested by materials engineer
 Copy of lab certification for each test facility that provided data if testing is not performed within GM
 Copy of the part drawing notes or math data that includes all of the material specifications
 Signed documentation stating the percent regrind used for parts tested (if applicable)
 Datapaq or oven chart equivalent
 Schematic indicating the location of part where film build measurements were taken
 Paint film thickness measurements per ISO 2808 - measure minimum of four areas per part (Exterior)
or three areas per part (Interior)

 GM9620M Film Build Chart for each coating (if applicable, in accordance with part drawing notes or
math file)

 GM approved and signed cure latitude chart for each coating (if applicable, in accordance with part
drawing notes or math file)

 Schematic indicating the location on the part from which the test samples were obtained
 White parts – reprocess twice for reprocess validation (Exterior)
 Signed documentation of reprocess procedure (Exterior)
 Signed documentation of sanding process (Exterior)
 Tested parts for review including adhesion tapes
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Table A15: PPAP Checklist

 Printout of APOPS Approval


 Test data for Table A3, A4 or A5 as applicable for component
 Proof of certification to ISO/TS 16949 or ISO/IEC 17025 if testing is not performed within GM
 Copy of the part drawing notes or math data that includes all of the material specifications
 Printouts of MATSPC approvals for all paints and materials used
 Paint film thickness measurements per ISO 2808 - measure minimum of four areas per part (Exterior)
or three areas per part (Interior and Underhood) for each program color

 GM9620M Film Build Chart for each coating (if applicable, in accordance with part drawing notes or
math file)

 Printout of Trim Transmittal for the production paint system in each paint color at the appropriate gloss
level (for Interior applications)

© Copyright 2012 General Motors Company All Rights Reserved

March 2012 Page 30 of 30

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