The electrocoat process consists of several systems working together. This makes troubleshooting a defect very difficult. This talk explains how the process of troubleshooting defects can be focused into three categories: process, chemistry and unusual conditions. A troubleshooting reference guide will also be provided as we discuss the disciplined approach of isolating components of your system to determine root cause and the appropriate countermeasure to take to correct a problem. Several useful analytical and laboratory tools will also be described.