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dell 6724U_A05-00

DELL CONTROLLED PRINT

Corporate Cosmetic Specification

Title: SPEC, DELL, COSMETIC, CORP-STD

Doc. Number: 6724U

Revision: A05-00

Authors: Pedro Alfonso, Paula Cox, Bobby Dean Landreth, Jim Slagle

Owner: Dell Experience Design Group

PROPRIETARY NOTE

This item is the property of Dell, Inc., Round Rock, Texas and contains confidential and trade secret information. This item may not be transferred from the custody of Dell, Inc., except as authorized by Dell, Inc. and then only by way of loan for limited purposes. It must not be reproduced in whole or in part and must be returned to Dell, Inc. upon request and in all events upon completion of the purpose of the loan. Neither this item nor the information it contains may be used by or disclosed to persons not having a need for such use or disclosure consistent with the purpose to the loan without prior written consent of Dell, Inc.

Table of Contents

1.Revision History (4)

2.Introduction (5)

2.1P URPOSE/O BJECTIVE (5)

2.1.1Purpose (5)

2.1.2Objective (5)

2.2S COPE (5)

2.3R EFERENCES (5)

2.4D EFINITIONS (5)

3.Document Requirements (6)

3.1P RODUCT S PECIFIC C OSMETIC S PECIFICATION (PSCS) OR ESG(E NTERPRISE S ERVER G ROUP -S ERVERS

AND S TORAGE)P RODUCT D ESIGN L ANGUAGE G UIDELINE D OCUMENT. (6)

3.2C ORPORATE C OSMETIC S PECIFICATION (CCS) (7)

4.Application (7)

5.Maintenance (7)

5.1PSCS (7)

5.2CCS (7)

6.Document Control and Distribution (7)

6.1D OCUMENT N UMBER A SSIGNMENT (7)

6.2D ISTRIBUTION (8)

7.Conflict Resolution (8)

8.Molded Plastic (8)

8.1M OLDED P LASTIC D EFECTS (8)

8.2L ENSES (9)

8.3L IGHT PIPES (9)

9.Sheet Metal (9)

9.1S HEET M ETAL D EFECTS (10)

10.Die Cast Cosmetic Surface Finish, (As Cast) (10)

10.1D IE C AST D EFECTS (11)

11.Painted/Coated Materials (11)

11.1P AINTED P ART D EFECTS (11)

11.2G ENERAL G UIDELINES (12)

11.2.1Finishes Comparison Panels / Approved Limit Samples (12)

11.2.2Performance Testing (13)

https://www.wendangku.net/doc/9010831590.html,bels/Printing/Silk Screening (13)

12.1L ABELS,P RINTED D EFECTS (13)

12.2O THER R EQUIREMENTS (13)

13.IMD Film (13)

13.1IMD F ILM D EFECTS (13)

14.Heat Transfer Film (14)

14.1H EAT T RANSFER F ILM D EFECTS (14)

15.Defect Appraisal (15)

15.1I NTRODUCTION (15)

15.2D EFECT I NSPECTION C RITERIA FOR ALL D ELL P RODUCTS EXCEPT ESG S HEET M ETAL (F OR ESG S HEET

M ETAL, REFER TO SECTION 15.3 FOR DETAILED INSPECTION CRITERIA.) (15)

15.2.1Introduction (15)

15.2.2Inspector Qualifications (15)

15.2.3Inspection Process (15)

15.2.4Accept/Reject Criteria (16)

15.3D EFECT I NSPECTION C RITERIA FOR ESG(S ERVERS &S TORAGE)N ON-D ECORATIVE S HEET M ETAL (18)

15.3.1Introduction (18)

15.3.2Inspector Qualifications (18)

15.3.3Inspection Process (18)

15.3.4Accept/Reject Criteria ESG Non-Decorative Sheet Metal (19)

16.Color (20)

16.1K EY C RITERIA (20)

16.1.1Definitions (20)

16.1.2Suggested Formulations of Dell Colors (21)

16.1.3Pigments/Dyes (22)

16.2D ELL C OLOR AND F INISH S TANDARDS (22)

16.2.1Dell Color Part Numbers (22)

16.2.2Dell Color Standards (22)

16.2.3Proper Care of Color Standards (22)

16.3I NITIAL M ATCHES (22)

16.3.1Number of Initial Match Samples (23)

16.3.2Size of the Match Samples (23)

16.3.3Surface Finish of the Match Sample (23)

16.3.4Gloss of the Match Sample (24)

16.4C OLOR/F INISH R EVIEW C RITERIA (24)

16.4.1Evaluator Qualifications (24)

16.4.2Color/Finish Review Process (24)

16.4.3Illuminants (24)

16.4.4Viewing Evaluation Requirements (25)

16.4.5Initial Match Qualification Report (26)

16.5C OLOR C ONTROL IN P RODUCTION (26)

16.5.1Production Lot Monitoring (26)

16.5.2Tolerances for Color on Production-level Parts (27)

17.Appendix A – Chassis Gap Design (27)

17.1D ESIGN G AP T OLERANCES (27)

17.2A CCEPT/R EJECT C RITERIA (28)

18.Appendix B – Checklist for Engineering Part Document (29)

19.Appendix C – Loose Conductive Particles on Sheet Metal or Cast Metal Parts (30)

19.1I NTRODUCTION (30)

19.2P URPOSE (30)

19.3G ENERAL D ESCRIPTION (30)

19.4T EST E QUIPMENT (30)

19.5T EST P ROCEDURE (30)

20.Appendix D – Dell, Inc. Product Color Evaluation Request (31)

21.Appendix E – Dell, Inc. Defect Inspection Template (31)

22.Appendix F – Dell, Inc. Color Document (31)

23.Appendix G – IMR Defects (31)

2.Introduction

2.1 Purpose/Objective

2.1.1 Purpose

Product cosmetics include the visual, auditory and tactile qualities which directly affect aesthetic satisfaction. In a marketplace where first impressions and perceived images heavily influence product acceptance, the appearance of a product can deliver the promise of excellence in performance and functionality. Attention to detail on the outside of the product sends an important message to the customer about total commitment from the company behind that product. Through high-quality, consistent product cosmetics, Dell can reinforce its dedication to long-term customer satisfaction. This document provides the cosmetic standards for use by Dell offices worldwide to maintain its competitive position while meeting its customers’ needs and expectations.

2.1.2 Objective

1.To provide a quantifiable baseline for judging cosmetic quality.

2.To provide a baseline for cosmetic level brand differentiation.

3.To provide a baseline for cost estimates by the Product Group, Production Engineering and Field Service.

4.To provide an acceptance criteria baseline for Purchasing to secure bids and contracts.

5.To provide an acceptance criteria baseline for Suppliers, Production Engineering and Incoming Quality. 2.2 Scope

This document is intended for worldwide use by Dell Business Units (Marketing, Product Group, Purchasing, Production Engineering, Manufacturing, Quality and Field Service) and associated suppliers. These standards are provided to facilitate consistency in the communication and resolution of cosmetic related issues.

2.3 References

The following documents may be used as references in regard to color specification. Color specifications, (see Color Document example in Appendix F), may expand on certain aspects of the test methods and supersede the documents listed below.

?ASTM D2244 Standard Method for Instrumental Evaluation of Color Differences of Opaque Materials ?ASTM D1729 Standard Practice for Visual Color Evaluation of Color Differences of Opaque Materials ?ASTM D4086 Standard Practice for Visual Metamerism

?ASTM D523 Standard Test Method for Specular Gloss

?ASTM D4459 Standard Practice for Xenon-Arc Exposure of Plastics Intended for Indoor Applications ?SPI Plastic Surface Finishes

2.4 Definitions

?Class 1 Surface: Visible on a constant, daily basis. This includes, but is not limited to, the top and front of

a computer or monitor.

?Class 2 Surface: Visible occasionally, as the sides of a unit.

?Class 3 Surface: Visible during normal customer maintenance, such as the back and bottom of unit.

?Class 4 Surface: Not normally visible. This encompasses all other surfaces which are not Class 1, 2 or 3.

3.Document Requirements

This specification identifies and defines two key document types.

3.1 Product Specific Cosmetic Specification (PSCS) or ESG (Enterprise

Server Group - Servers and Storage) Product Design Language

Guideline Document.

All Dell non-ESG products that require deviation from or additional specification to the CCS require a PSCS document.

All Dell ESG products that require deviation from or additional specification to the CCS require an ESG Product Design Language Guideline and / or a PSCS.

The PSCS or ESG Product Design Language Guideline document details product-specific cosmetic information. The PSCS or ESG Product Design Language Guideline should contain assembly tolerances, definitions of unique cosmetic elements, acceptable limits and any deviations from the CCS. Mechanical Engineering and Industrial Design are jointly responsible for creating the PSCS or ESG Product Design Language Guideline document.

Each PSCS or ESG Product Design Language Guideline shall include, at a minimum, the following sections:

1.Purpose & Scope (included in the Introduction paragraph)

2.Visual Diagram & Inspection Summary

This section should be focused, concise and contain all critical information.

3.Reference Documents (included in the Introduction paragraph)

When the inspector needs additional information beyond the Visual Diagram & Inspection Summary, the PSCS References Paragraph will provide the specific additional information pertaining to the product.

Reference documents may include Dell Corporate Cosmetic Specifications or other industry standards as applicable.

When conflicts arise between the CCS & PSCS or ESG Product Language Design Guideline Document, see Section 7.0 Conflict Resolution

3.2 Corporate Cosmetic Specification (CCS)

The CCS document serves as a baseline for communicating cosmetic requirements for all Lines of Business, (LOB). Cosmetic specifications in this document are identified in separate sections for each of the following: ?Molded Plastic

?Sheet Metal

?Die Cast

?Painted/Coated Materials

?Labels/Printing/Silk Screening

?IMD Film

?Heat Transfer Film

?Defect Appraisal

?Color

?Dell Logo

?Chassis Gap

The CCS is to be used as a basis for RFQ, initial design and ongoing quality criteria. Unless the PSCS, drawings, or other specifications clearly state a different requirement, the CCS shall apply and be in effect.

4.Application

The use of the PSCS will minimize the time and effort required to bring a product to market by:

1.Enabling Dell to call out on the PSCS only those items that vary from the CCS.

2.Providing Procurement with clear cosmetic requirements for communication to suppliers.

https://www.wendangku.net/doc/9010831590.html,municating cosmetic requirements earlier in the design phase to facilitate more accurate cost estimate.

4.Defining requirements early in the design phase to help suppliers design and implement the necessary

processes to support key cosmetic requirements.

5.Clearly establishing cosmetic requirements within the Product Features Guide

6.Providing an easy reference for all engineering drawings that refer to a PSCS or the CCS.

7.Providing supplemental ongoing quality requirements for the specific product.

5.Maintenance

5.1 PSCS

Changes to the PSCS’s must occur under ECO control and will require approval by designated document approval authorities.

5.2 CCS

Changes to the CCS must occur under ECO control. The Dell Experience Design Group, (EDG), is responsible for reviewing the CCS as needed. Dell EDG shall update and maintain this Corporate Cosmetic Specification to reflect current market, industry and Dell practices.

6.Document Control and Distribution

The Corporate Cosmetic Specification (CCS) and the Product Specific Cosmetic Specifications (PSCS) will be placed under the Part Change Order (ECO) control process.

6.1 Document Number Assignment

The PSCS shall be assigned a Dell “part number” through Agile.

6.2 Distribution

The documents will be published and posted in Agile.

7.Conflict Resolution

If conflicts over cosmetic requirements arise between Dell and a Supplier, the final interpretation will be made by the PSCS owners or ESG Product Language Design Guideline Document owners with support from Dell Procurement and Dell Quality.

When the 6724U Corporate Cosmetic Specification conflicts with the Product Specific Cosmetic Specification or ESG Product Language Design Guideline Document, the Product Specific Cosmetic Specification or ESG Product Language Design Guideline Document shall always take precedence and override the CCS. Likewise, specific product design documentation for parts or assemblies (e.g. Level 5 assembly documentation) supersedes the 6724U CCS and the applicable PSCS or ESG Product Language Design Guideline Document.

8.Molded Plastic

This paragraph will provide a uniform worldwide standard for the inspection of injection molded parts and assemblies. These guidelines will be used by Dell suppliers, as well as Dell personnel involved in first article inspection, purchasing, incoming inspection, assembly, ongoing quality and final audits at all Dell and supplier manufacturing sites. The end goal is to provide Dell manufacturing sites and Dell suppliers with best-in-their-class components and assemblies.

8.1 Molded Plastic Defects

?Blush: Discoloration or change in gloss, usually at gate areas or where wall thickness changes.

?Bubbles: Transparent parts or void pockets (may appear as a blister or bulge on colored parts).

?Burns: Brown marks, spots or streaks (usually associated with poor venting of gasses during molding).

?Cold Slug: Visible inhomogeneous melt from the first material to enter the mold during injection.

?Contamination: Discoloration from foreign material or foreign material embedded in the surface.

?Cracking: Splitting or fissures causing separation of the material.

?Crazing: Tiny cracks or white marks that are visible due to stress exerted on the part.

?Delamination: Separation of the layers of plastic.

?Discoloration: Inconsistent color or any deviation from the color standard.

?Drag Marks: Scratches from the plastic scraping against the mold during part ejection.

?Flow Marks: Directionally off-tone wavy or streaked appearance of a surface.

?Flash: Excessive plastic along the parting line or mating surface of the mold.

?Gas Marks: Burn marks or dark discolored streaks usually caused by inadequate venting of the gasses trapped in the mold during the injection phase.

?Gouge: Surface imperfection due to abrasion, nicking or poor trimming.

?Grease: Machine lubrication on the part.

?Haze: Cloudiness of a transparent part.

?Marbling: Colored streaks due to incomplete mixing of color.

?Nicks: Surface scratches or indentations due to mis-handling of part.

?Particles: Small discolored spots or matter embedded in material.

?Pin Push: Distortion or protrusion caused by ejector pin pushing into part.

?Pitting: Crater-like imperfections in the material.

?Porosity: Holes or voids in the material.

?Protrusion: Raised area on a surface, such as a blister or bump.

?Pulling: Part distortion caused from plastic sticking in the mold.

?Scratch: Surface imperfection due to mis-handling.

?Shine: Glossy or shiny areas on textured surfaces.

?Shorts/short shots: Missing material due to incomplete filling of the mold.

?Sink: Surface depression that occurs during cooling phase of the part.

?Specks: Small discolored spots or matter embedded in the material.

?Splay: Off-colored streaking (often silver-like) caused by moisture in the material or thermal degradation of the resin during processing.

?Weld Lines: Appears as a line where two or more fronts of molten plastic converge (also called knit lines).

?Witness Lines: A visible line formed by the junction of two pieces of steel in the mold.

8.2 Lenses

All lenses are Class 1 unless otherwise specified on part drawing.

Surface finish of all exposed surfaces for Lenses requires SPI A-2 polish unless otherwise specified. Note: Some areas may specify texture.

8.3 Light pipes

All light pipes are Class 1 unless otherwise specified on part drawing.

Surface finish of all exposed surfaces for light pipes requires SPI A-2 polish unless otherwise specified. Note: Some areas may specify texture.

9.Sheet Metal

This paragraph will provide a uniform worldwide standard for the inspection of sheet metal parts and assemblies. These guidelines will be used by Dell suppliers, as well as Dell personnel involved in first article inspection, purchasing, incoming inspection, assembly, ongoing quality and final audits at all Dell and supplier manufacturing

sites. The end goal is to provide Dell manufacturing sites and Dell suppliers with best-in-their-class components and assemblies.

9.1 Sheet Metal Defects

?Abrasion: A scuffed or rubbed surface imperfection

?Arcing Marks: Marks in the part caused by the part coming into contact with the plating tank.

?Brush Finish: Finish produced by texturing with brushes or other abradants such as glass/nylon rollers.

?Burr: Ragged or sharp protrusions on edges or holes

?Dent: A depression or hollow made by impact or pressure.

?Pitting: Depressions in the material surface which result from the removal of roll inclusions and/or oxidization.

?Scratch: A mark in the surface that is characterized by its long length relative to its depth and width.

?Slug: A small piece of material produced during stamping when piercing a hole.

?Slug Marks: Dents caused when slugs are trapped between the mating die surfaces and the sheet metal.

?Water Spots: Discolorations on sheet metal caused by impurities in the wash.

?Wipe marks: Abrasions caused from the forming tooling wiping the material during a forming or bending operation.

?White Rust: Powdery substance resulting from zinc coating oxidization.

10.Die Cast Cosmetic Surface Finish, (As Cast)

This paragraph will provide a uniform worldwide standard for the inspection of die cast parts and assemblies. These guidelines will be used by Dell suppliers, as well as Dell personnel involved in first article inspection, purchasing, incoming inspection, assembly, ongoing quality and final audits at all Dell and supplier manufacturing sites. The end goal is to provide Dell manufacturing sites and Dell suppliers with best-in-their-class components and assemblies.

The engineer should specify the minimum, (lower number), surface finish requirement per one of the classifications shown below for “As Cast” metal parts that do not have any secondary painting or powder coating.

10.1 Die Cast Defects

?Cold Shut: A casting defect caused by imperfect fusing of molten metal coming together from opposite directions in a mold.

?Rubs: Blemishes on the cast surface created due to soft part ejection impact onto other parts, machinery, floor, etc.

?Surface Porosity: Holes in the casting due to 1gases trapped in the mold, 2reaction between molten metal and moisture in the sand, or 3imperfect fusion of chaplets with molten metal,

?Hot Tear: Irregular shaped fracture in a casting resulting from stresses set up by steep thermal gradients within the casting during solidification.

?Inclusions: Particles of slag, refractory materials, sand, or deoxidation products trapped in the casting during solidification.

11.Painted/Coated Materials

This section will provide a uniform worldwide standard for the inspection of coated parts and decorative plastic parts with integral molded in finishes. These guidelines will be used by Dell suppliers, as well as Dell personnel involved in first article inspection, purchasing, incoming inspection, assembly, ongoing quality and final audits at all Dell and supplier manufacturing sites. The end goal is to provide Dell manufacturing sites and Dell suppliers with best-in-their-class components and assemblies.

11.1 Painted Part Defects

?Orange Peel: Film that has the physical appearance of an orange peel.

?Fat Edge: Visibly thicker paint build near edges or through-holes.

?Dry Spray: A rough, textured surface often confined to a small area.

?Sag or Run: Tiers, drips, or curtains of paint on vertical or inclined areas.

?Color Mismatch: Finished panels do not match color standard.

?Fisheye: Small, crater-like opening in the finish after it has been applied.

?Dirt: Small bumps deposited in, on, or under the paint film.

?Peeling: Any paint layer that peels off substrate or underlying coating layers.

?Solvent Trap or Popping: A "goose pimple" or volcano appearance in paint film which, on close examination, frequently has small holes in the center of the bumps.

?Mottling: Spotty, non-uniform, blotchy appearance of metallic paint.

11.2 General Guidelines

For decorative surfaces (Class 1, 2 and 3), the Inspector should review each surface for uniformity of appearance in color, texture and gloss, as well as the absence of imperfections. For non-decorative surfaces (Class 4), the Inspector should review finishes for completeness of coating coverage and absence of functional defects such as blisters, bubbles, dirt, scratches, stains, burning, corrosion, dents and damage.

11.2.1 Finishes Comparison Panels / Approved Limit Samples

Appearance acceptance or rejection of finished parts should be based upon the Dell approved comparison panels or Dell approved limit samples. The panels or limit samples should be examined and renewed, and or replaced, every six months or as needed. Suppliers are responsible for maintaining and updating comparison panels or approved limit samples as needed to ensure required product quality. Any new or updated comparison panels or limit samples require Dell ID approval. When the class of finish is not otherwise specified, the part quality inspection criteria will be as follows:

?Painted Class 2

?Plated Class 4

?As Molded Class 4

The color, texture and gloss of decorative finishes should be determined against a neutral background by visual comparison to a Dell Color Master Standard Plaque, (CMSP). All surfaces should be inspected with a BYK Gardner 60 degree specular gloss meter unless otherwise noted on the part drawing.

These stated gloss values are typical for manufacturing purposes only, and they will vary depending on the base material & manufacturing process.

Although there will be exceptions, the following are typical terminology used for gloss:

?Matte 5.5gu

?Satin 17gu

?LoGloss 25gu

?SemiGloss 50gu

?HiGloss (monocoat) 80gu

?HiGloss (topcoat) 90gu

The gloss designation is typically added after the Dell color name, for example, “Dell Standard Black, HiGloss.”

Gloss values may be limited by specific regulatory systems, such as GS Mark. For these systems, gloss must be designed and specified to comply with regulatory limits. Typically, maintaining a gloss of less than 20 units at 60 degrees will fulfill most regulatory requirements.

Gloss specification and tolerance for coated surfaces is specified on the applicable Dell Color Document.

11.2.2 Performance Testing

All painted and / or coated materials must meet requirements as defined per Dell document 85FMR.

All painted and / or coated materials testing must be submitted in Dell format ENG0000232 (finish supplier report) or ENG0000230 (finish applicator report) and approved by Dell. Note: ENG0000230 finish applicator report test results must be included in applicable PPAP documents under the Additional Documentation tab and must be approved by applicable engineers. ENG0000232 finish supplier report test results must be submitted directly to Dell CMF for approval.

https://www.wendangku.net/doc/9010831590.html,bels/Printing/Silk Screening

This paragraph will provide a uniform worldwide standard for the inspection of printed labels and overlays. These guidelines will be used by Dell suppliers, as well as Dell personnel involved in first article inspection, purchasing, incoming inspection, assembly, ongoing quality and final audits at all Dell and supplier manufacturing sites. The end goal is to provide Dell manufacturing sites and Dell suppliers with best-in-their-class components and assemblies.

12.1 Labels, Printed Defects

?Fish Eye: Undesirable circular flaw in the printed image usually caused by bubbling of the ink.

?Ghost Image: A second image that is slightly visible behind the desired print.

?Moire: An undesirable optical effect that can occur when printing halftones or four color process.

?Mottle: A spotty or uneven printed surface with is most apparent in solid areas.

?Pin Hole: A defect or void that appears in the desired print.

?Spider Webbing: Small strings of ink that appear around the edge of print. These are usually caused by static electricity or surface tension problems.

?Streaks: Elongated defects in a printed image.

12.2 Other Requirements

A reference copy of the artwork will be visually compared with the label/overlay to inspect for completeness and for artwork fidelity. All letters, characters, borders and backgrounds must be complete, and all lettering must be sharp and legible.

13.IMD Film

This paragraph will provide a uniform worldwide standard for the inspection of IMD film decoration. These guidelines will be used by Dell suppliers, as well as Dell personnel involved in first article inspection, purchasing, incoming inspection, assembly, ongoing quality and final audits at all Dell and supplier manufacturing sites. The end goal is to provide Dell manufacturing sites and Dell suppliers with best-in-their-class components and assemblies.

13.1 IMD Film Defects

?Washout: The displacement of ink from the film by plastic flow.

?Contaminants: The entrapment of visible particles, etc. between the film and plastic or embedded in the film surface.

?Wrinkle: Wrinkle, fold, or crease in the film from inadequate film positioning, injection velocity, or loose film which most often occurs near corners or edges where part radii are extreme.

?Film Flash: Film remnants that extend beyond the part or in through-holes.

?Breakage: Breaks or gaps in the film where underlying substrate is visible.

?Film Tear:Breaks or gaps where underlying substrate breaks through the ink / film and is visible on surface of the part.

?Mis-registration:Improper alignment of film pattern, icon, etc. with the part that is out of specified location tolerance.

?Scratch: A mark in the surface that is characterized by its long length relative to its depth and width.

?Poor Opacity/Coverage: Inadequate hiding power of the film to maintain proper color or adequate contrast.

?Inadequate adhesion: Any peeling, cracking or delamination from substrate or underlying layers.

?Dents: Any indentation into the part that is visible on the decorated surface.

?Color Contamination or Discoloration: Any unintentional visible variation in color.

?Missing Artwork: Incomplete image or icon.

For Examples see Appendix G.

14.Heat Transfer Film

This paragraph will provide a uniform worldwide standard for the inspection of heat transfer film decoration. These guidelines will be used by Dell suppliers, as well as Dell personnel involved in first article inspection, purchasing, incoming inspection, assembly, ongoing quality and final audits at all Dell and supplier manufacturing sites. The end goal is to provide Dell manufacturing sites and Dell suppliers with best-in-their-class components and assemblies.

14.1 Heat Transfer Film Defects

?Contaminants: The entrapment of visible particles, etc. between the film and plastic or embedded in the film surface.

?Wrinkle: Wrinkle, fold, or crease in the film from inadequate film positioning, improper application, or loose film.

?Film Flash: Film remnants that extend beyond intended decorated surface or in through-holes.