Quality in the automotive industry today faces far greater demands than ever before. It is no longer just about whether the surface of individual components is functional and “looks good.” Manufacturers must meet OEM standards, ensure process stability, maintain functional properties, comply with environmental manufacturing parameters, and respond to new requirements associated with the rise of electromobility. In this interview, Jan Kysela, Head of Quality at Automotive Painting Partners, explains why a systematic approach to quality is the foundation of success.
Mr. Kysela, you have been serving as Head of Quality at Automotive Painting Partners (APP) since 2020. What does this role involve?
At Automotive Painting Partners, I am responsible for both process and system quality across the entire company. This includes managing system and customer audits, leading the quality team, and most importantly translating the requirements of general standards and specific OEM standards into our internal rules. Simply put, what is written in standards or customer manuals must be translated into everyday practice on the production line. And it must work long-term – not just during an audit.
On your website, Automotive Painting Partners states that quality is not seen as a goal but as a fundamental principle of how you operate. How does this approach influence cooperation with customers such as OEMs and Tier 1 suppliers of well-known brands?
We primarily view quality as a tool for risk management, project planning, and long-term competitiveness. It is not just about inspecting finished parts but about systematic work from the initial inquiry all the way to stable serial production. For automotive manufacturers, this leads to a clear conclusion: the earlier we openly and technically define the requirements for cathodic dip coating, functional surface properties, and related processes, the more stable and predictable the entire project becomes in the serial phase. This is where the true level of systematically managed quality becomes visible – the ability not only to respond to requirements but to actively prevent future problems.
In the past, quality was mainly associated with measuring coating thickness and visual surface inspection. How has everyday practice changed?
The core objective remains the same – delivering a high-quality and functional product. However, the path to achieving it is far more complex today. In cathodic dip coating, quality is evolving significantly due to new materials used in welding and component design. We work with different types of steel as well as aluminium and often deal with combinations of materials. For some parts, adhesive bonding follows our process, which means the surface must also meet requirements for surface tension and other parameters important for adhesion.
In the automotive industry, both technological capability and the flexibility to respond to specific manufacturer requirements are crucial. How do you manage this in practice?
Yes, material changes are currently a major topic in cathodic dip coating. That is why we place enormous emphasis on project management. We have a strong project team that communicates closely with the customer already in the early stages. Everything that is clarified and properly set at the beginning – from design details to the testing plan – works throughout the entire implementation phase. If something is underestimated at the start, it will come back during serial production – and in automotive, that is simply not acceptable.
Electromobility is transforming the automotive industry. Has it also fundamentally changed the field of quality?
Yes, quite significantly. In some applications, there is still no long-term verified “one correct solution.” Requirements from automotive manufacturers for coating components used in electric vehicles can sometimes be extremely strict – even excessively so. That is why it is essential to clarify at the start of a project what is a genuinely functional requirement and what is merely a preventive safety margin. Our goal is to set quality standards that are fully functional while also technologically and process-wise stable.
Electric vehicles also have different requirements for surface treatment properties. How do these new trends affect your daily work?
Everything revolves around the requirements that the customer presents at the beginning during the inquiry phase. The more information we receive at this stage, the more effectively we can support subsequent processes such as bonding or chemical resistance. Quality therefore becomes not just a reaction to a problem but a tool that helps prevent risks in serial production from the very beginning.
Automotive quality today relies not on a single certification but on an entire ecosystem of standards. How do you maintain these standards, and what is most important for your partners?
The basic certification remains the IATF 16949 standard, which ensures compliance with the strictest OEM requirements. However, new standards are constantly being added – from process audits such as VDA 6.8 to information security requirements within TISAX, among many others. At APP, we monitor all new regulations well in advance. We analyse them, appoint responsible persons for their implementation, and set up processes so they function in practice, not just on paper. After verification by a third party, we obtain the necessary certifications and approvals. In short, quality for us is a system – not a one-time project prepared just before an audit.
Engineers are often concerned about coating inside cavities and internal spaces of components. How do you ensure uniform KTL coating thickness even in areas affected by the Faraday effect, where corrosion risk is highest?
Once again, we return to the project phase. It is crucial to become involved in the discussion already during the component design stage and communicate directly with the customer’s design team. If the design incorporates properly dimensioned openings and structural features that allow optimal flow of the coating bath and electric field, we can achieve very good coverage even in cavities and hard-to-reach areas. However, it must be said openly that physics cannot be overcome. If the design does not allow the technologically correct course of cathodic dip coating, achieving 100% coating coverage in internal spaces is not possible. That is why these questions must be addressed as early as possible.
“Green manufacturing” is a clear industry trend. Are environmental parameters now as important to customers as technological ones?
Absolutely. We are certified according to ISO 14001, which defines requirements for environmental management systems and continues to evolve. However, it is not enough simply to “be green”. You must also be stable and repeatable. In practice, this means balancing the elimination of heavy metals, reducing VOC content, and maintaining a completely stable production process. At APP, we do not treat environmental parameters as marketing but as a standard. We have strict process controls, regular monitoring of bath parameters, and comprehensive output testing. Environmental responsibility and technical quality are not in conflict for us – they must go hand in hand.
Can your extensive experience with automotive standards be applied to other industries as well?
The automotive industry is known for its extreme rigor and strict requirements for process stability. These principles can be applied almost anywhere. The key question is always the final use of the product and its requirements. Wherever there are high demands for reliability, long service life, and documented quality, such a system brings clear benefits.
APP is part of the strong Colegium Holding group. Does this connection also bring advantages in the area of quality, for example through sharing experience and best practices?
Definitely. Quality is not an isolated discipline. The broader the context, the better we can anticipate risks. Sharing experience across the Colegium Holding group brings significant value to APP’s quality processes. Colleagues from other member companies have experience ranging from product development to testing in real operation. All of this knowledge helps us – especially during the launch of new projects.
Where do you think the role of the quality department at APP will move in the coming years?
Quality requirements will continue to become stricter – technically, environmentally, and legislatively. Our goal is therefore to be prepared in advance. We do not want to wait until market pressure or regulations force us to react. We want Automotive Painting Partners to be the first choice when selecting a supplier of cathodic dip coating – not only in the Czech Republic and Central Europe, where we are already among the largest KTL providers, but also in other regions.
Thank you for the inspiring interview!
