Plating) English Madhan-1

8/4/2019 Plating) English Madhan-1

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HMC - HMI

Plating Standards

2006. 08.


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Contents

1. Plating Process Flow

2. Plating process Main control point

3. Main control points in detail

4. Improvement Cases

- Zn, Zn-Ni Plating

- Ni-Cr Plating


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1. Plating process flow


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1. Plating Process Flow

Degreasing

Remove oil

Acid Pickling

Remove rust

Plating

In put WaterWashElectrical

Degreasing

Plating

Remove Acid Thorough

cleaning

Inspectionispatch Chromating

Chromating forappearance

Drying

Drying

Thickness &

Salt spray test

Etc.

Zn_Plating


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2. Plating process

Main control point


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Index Main control pointMaterial 1) Incoming Plating chemical and material inspection

Machine2) Calculation of surface area => Decide input chemical

amount => Establish Plating process parameter(current & time)

3) Filtering system ( Oil and Water, Dust)

Method

4) Standardize process parameter => Check frequently( SPC for plating thickness, Solution , Machine ,Current & Time etc.)

5) Automatic inhibitor addition ( Using electric power) :Bright and semi bright is essential6) Another additional liquid tank install and control liquid

density level constantly7) Inspection : Plating thickness & Blister. Etc.

2. Main control point of Plating process


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Index Important point

Man8) Qualification : Plating solution inspector, Plating quality

inspector (Thickness etc.), Plating operator(Temperature & time)

Environ-ment9) Satisfaction for environment spec : Hexavalent chromate

to trivalent10) Waste water controlling system

Essentialpoint1) Ni-Cr : External part : Micro Porous Nickel,2) Zn Ni : Ni Extraction rate ,Additional tank to maintain

Zn-Ni Solution density3) Zn, Zn-Ni : Chromating process

2. Plating process Main control point


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3. Main Control Point in Detail


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Index Material- Incoming Inspection

Picture

Process - Incoming InspectionControl

Parameter- Material Rust & Oil prevention, Heat treatment part surfacedefects dust Contamination, Baking, Avoid mix up of material andother parts

Remarks-Inspection Control (Approach/Daily report), Control History forProblem

Method MachineMaterial Quality

RecordingncomingInspectionMaterialIncoming

[ MaterialInspectionReport]


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Index Material Environment regulation ( 3 Chrome Plating )

Picture

Purpose - Environment regulation complianceECStandard - 6 Chrome prohibited, Green Environment Process

Remarks - Until Jun06


Green EnvironmentChromate Plating picture


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Index Material- Storage Status

Picture

Check - Material/Incoming Part Storage StatusStandard - 3C/5S, Identification, FIFO- Plating Thickness IndexRemarks - work order, Material flow movement Status must be clear


Plating chemical Storage Material Storage


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Index Material -3C,5S

Picture

Check - 3C/5SStandard - Material warehouse, Location , Identification & FIFORemarks


Plating chemical Material, Process, Storage


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Index Method Pretreatment - Degreasing

Picture

Check Degreasing Process ControlStandard Control parameter (Temperature, Density, Water Contamination)Remarks - After Degreasing check Water dropping =>Check Degreasing Status


Pre Degreasing ElectricalDegreasingain Degreasing (AcidPickling)

Water dropping=>Defect

Water Spread=>OK


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Index Method Pretreatment - Acid pickling

Picture

Process Acid picklingStandard - Control parameter (Temperature, Density ,Current & Time)Remarks Analyze chemical once in a week , Setup current and TemperatureMeasure


Acid pickling


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Index Method-Condition Control

Picture

Check item Working ConditionApproach - Plating thickness Control/Density/Current/Temperature/Remarks


Control plan Work Approach


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Index Method- Condition Control- ( Eg.: Plastic Plating)

Picture

Remarks


Parameter HMC SPEC1 ST VNR

SPECUCL & LCL


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Index Method-Work standard approach

Picture

Check item Plating / Chromating working Approach FollowApproach - Working Approach Follow /Plating chemical input History ControlRemarks


Work Approachiquid charging Historyolution Analysing


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Index Method- Plating solution Analysing

Picture

Check item Plating solution AnalysingApproach - Solution Status/ Analysing daily report Control/Action checkRemarks


Solution Analysing Plating solution Analysingworking report


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Index Method- Plating/ Chromating solution Analysing PlatingExample

Picture

Remarks -Example for Plastic Plating



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Index Method-Self Inspection

Picture

Check item Process Self Inspection StatusApproach Degreasing, Acid pickling / Plating Process / Last process=>Process worker Self Inspection and reportRemarks


Degreasing Waterdropping

Adhesiondestructive test

Self Inspectionreport

Incoming SelfInspection


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Index Method-Water cleaning Process

Picture

Process Water cleaning processStandard - Process Approach Follow Condition Control (Density Analysing, Overflow, Water cleaning , Contamination)Remarks


OVER FLOW


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Index Method-Water Cleaning Process

Picture

Remarks -Shower Water cleaning



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Index Method-Water cleaning Process

Picture

Remarks -Shower Water cleaning


Water cleaning

BarrelPlating


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Index Method-Drying

Picture

Process DryingStandard -Control point (Drying period, Temperature, Input quantity ,Drying method, scratch, Hydrogen embrittlement)Remarks


HOT AIR


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Index Method-Tracing Control

Picture

Check item Material traceabilityApproach - Tracing / prevent mix up Control- LOT Control and Process moving tagRemarks -Part Incoming ~ Plating ~ Dispatch Tracing Control Status Check



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Index Method-Solution feeding Automatic

Picture

Process Solution feeding AutomaticStandard Using Electrical power feeding Plating solution, Plating chemical supplyAutomatically (Install Another additional tank )Remarks


Solution feeding Automatic


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Index Method-Another additional tank

Picture

Facility Another additional tankStandard - Use Another additional tank and control stable Density- install low Electrical instrument to remove the metallic dustRemarks


Low Electricalmesh

Anotheradditional tank


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Index Method-Condition Control F/P

Picture

Fool proof Condition Control F/PStandard Alarm or automatically controlled when problem happen(Temperature, Time, etc. )Remarks -300 % Control (First step : Fool proof , second step : Self inspection ,Third step : Manager cross checking)


Alarm when beyond the Spec.


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Index Machine Daily check and History Control

Picture

Check item Machine Daily check, Periodical Check, History ControlStandard - Check Status and Problem, Action HistoryRemarks


: 2002. 06

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1

2

3

1/

1

2

3

* D3 * ( => => )

( ->->

( ->->

5~7kgf/

/

( ->->

-Picture and location-Record the quantity


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Index Machine-Environment Machine

Picture

Check item Environment Instrument certification /ManagementStandard Waste water / Ventilation Gas/Smell/Gas ControlRemarks


Ventilation duct Waste water treatment


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Index Machine Cleaning Status

Picture

Check item Main Machine Cleaning StatusStandard - Machine Cleaning Status- Floor water leakage and Machine Rust etc..Remarks


Machine RustExample

cover


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Index Machine-RACK Control

Picture

Check item RACK Control/Spare part/MaintenanceStandard -RACK Contact point Status, another Storage location,Remarks


Rack Control


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Index Machine-Bus Bar, Pipe

Picture

Check item Cathode , Anode Color IndexStandard - DC Cathode ,Anode Color Index- Pipe and Electrical wire managementRemarks


Saddle Electricalimprovement(Water circulation)node, Cathode Color Index


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Index Machine- Input Qty Control,

Picture

Check item Process Condition ApproachStandard Decide input quantity with Plating surface,Remarks


Input Quantity Approach


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Index Machine-Filtering System, Oil Separator

Picture

Check item Filtering SystemStandard Filtering System, Oil SeparatorRemarks


Filtering System : Oil Separator

Water in

Oil

OVERFLOW


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Picture

Check item Filtering SystemStandard Oil SeparatorRemarks


Oil Separator

Water in

Oil

OVERFLOW

Big plant type


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Picture



Small plant type


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Picture



Over flow

Separating tank

1st. degreasing2nd. degreasing


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Index Quality-Final Inspection Method

Picture

Check item Final Inspection Method _ ApproachStandard - Inspection Approach, Master sample, Vendors Plating Spec.- Inspection requirement FollowRemarks


Master Adhesion Inspection


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Index Quality-External View Inspection

Picture

Check item External View Inspection, History managementCheckpoints - Blister, Gas, Crack, Pinhole, Dust, Stain mark

Remarks



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Index Quality-Plating Inspection

Picture

Check item Final Plating InspectionStandard - Master sample- Plating Thickness and HardnessRemarks


Plating ThicknessInspection X-RAY Inspection instrument


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Index Quality- Anti rust testing

Picture

Check item Check for rustStandard - Yearly plan for Rust checking test and resultRemarks


Yearly plan,results

Salt spray TesterASS Tester


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Index Quality-Laboratory and Inspection instrument

Picture

Check item Laboratory Control and Test statusStandard - Plating Thickness, Temperature, Density, Current, Salt spray testRemarks -Prepare essential Measuring Instrument for each plating type


Laboratory Thickness InspectionInstrument Rust testInstrument


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Index Quality-Laboratory and Inspection instrument

Picture

Remarks -Prepare essential Measuring Instrument for each plating type


Solu-tionX-RAY

HullCell test

Necessary


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Index Quality-Final Storage

Picture

Check item Final Storage managementStandard -Another Storage Location, Cleaning management, Approach BOX,PALLET, Separating paperRemarks



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Index Quality-Plating Qualification

Picture

Check item QualificationStandard 1. Solution analyser, 2. Final inspector, 3. Process operatorRemarks


qualificationPlating solutionMeasurement Plating partInspection


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4. Improvement cases Zn, Zn-Ni

Plating


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Before After

Input amount of component basedOn experience Surface area calculated for materialinputProblem Action

Title Calculation of surface area.Method


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Before After

( + ), ( - ) NoIdentification ( + ), ( - ) Identificationroblem Action

Title Bus Bar ColourMachine


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Before After

Suction Duct Only PUSH FAN Install VentilationEfficiency UpProblem Action

Title PUSH FAN InstallationENVIRONMENT


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4. Improvement cases Ni-Cr

Auto feeding


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Auto feeding

Title Plating solution auto feeding methodBefore After Remarks

Bright metal feeding machine

Low electrical mesh


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TitleLow Electrical meshing Low Electrical meshing

Action Action Effect high

MaterialLow electrical mesh to remove metalcontamination

Remove metal contamination

Circle type Wave type


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TitleBefore After

Problem Action F/P installed time and temperatureControlled automatically

MachineAutomatic temperature control

F/P Not installed


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TitleBefore After

Problem Action Overflow preventive systemcontamination controlled

MachineNi plating tank overflow

No overflow system.Contamination is not controlled(Bright metal finishers India)

Ni solution Overflow


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TitleBefore After

Problem Action Overflow preventive systemcontamination controlled

MachineNi plating tank overflow

No overflow system.Contamination is not controlled(Bright metal finishers India)


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TitleBefore After

Problem Action Anode sleeve

MachineNi Plating process Anode cover

Anode Bus Bar Rust


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TitleBefore After

Problem Action PVC Material saddle clean

MachineNi Plating process Saddle Improvement

Metal plate saddle heavy rust


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TitleAdhesion test Adhesion test sample

Action Action Adhesion test sample retained

MethodSelf Inspection (Adhesion)

Adhesion test


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TitleBefore After

Problem Action certification

MethodExplosion Test in the atmosphere


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TitleBefore After

Problem Action use picture

MethodWork Approach with picture

no picture

Picture


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TitleBefore After

Action Action FIFO established and arrangedproperly

MaterialArranging Bright metal location

Bright Metal boxes not arrangedproperly


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Plating) English Madhan-1