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2011-28-0073 A Study on Spectrum of Lights – Quality Retrospective P.K.GOPINATH,J. ARTHUR DEVADAWSON, R.RADHAKRISHNAN AND M.NANDAKUMAR FORD INDIA PVT LTD Copyright © 2011 SAE International ABSTRACT Modern manufacturing demands zero defects of extremely low defect rates, often measured in parts per million. Customer awareness regarding product quality has caused inspection process to become an important factor in manufacturing industries. Stated, simply, the inspection process is a careful search for non- conformities in an item. The two functions that are center to all inspection tasks are visual search and decision making. Innovative ways of identifying defects in most effective manner is the most important criteria in visual inspection method. Visual Inspection is commonly defined as "the examination of a material, component, or product for condition of non-conformance using lights and eyes”. The quality of the visual inspection are primarily affected by ? Quality of the detector ? The lighting condition Lighting condition play an important role in visual inspection. To make visual search more easy, simple and innovative, need to provide appropriate lighting condition and required color spectrum of lights which helps the inspector to capture the minor defects also in the parts visually. We need to provide an innovative ways of identifying defect in more cost effective manner. A detailed study was conducted to identify the required color spectrum which identifies and captures the minor defects with low cost. This study deals with the wavelength and characteristics of colors which enables vision to capture the minor defects of sheet metal stamped parts so as to reduce the scrap and rework cost and to provide a good quality vehicles. This paper describes the effective use of spectrum of lights to identify and capture the minor defects with low cost. INTRODUCTION Sheet metal components for a vehicle manufacturing can be classified as skin and skeleton panels. Skin panels form the outer surface of the vehicle and skeleton panel form the inner surface of the vehicle. Outer surface of the vehicle serves both in term of protection and appearance. The outer surface of the vehicle after painted looks very glossy which attracts the customer. The glossy nature of the paint will highlights minor defects in the skin panels of painted sheet metal components. These defects cannot be removed in the painted components. So it is absolutely necessary to produce sheet metal components free from all defects such as dents, bumps, waviness, thinning and other surface defects. DEFECTS IN SKIN PANELS The defects in the skin panels can be ? Dimensional defects ? Surface defects DIMENSIONAL DEFECTS – Dimensional defects in the sheet metal skin panels can be defined as the objective measurement not meeting the design intent. This can a change in hole size, trim edge less or more etc. SURFACE DEFECTS – Surface defects in the sheet metal skin panels can be defined as the defects