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Adam Brumfield (Quality
Manager) inspects the first production brake anchor part plated
with zinc cobalt with a trivalent black chromate and topcoat.
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Industry in the Old South is changing. Textile mills and furniture
manufacturers once ruled; however, a new leader has emerged: automotive.
Roy Metal Finishing, Greenville, SC, is realizing this and is implementing
changes that will help the 42-year-old company keep pace both technically
and productively with this demanding industry.
According to John Pazdan, company vice president, “It became
clear to us a few years ago that our automotive customers were expecting
more from their outsourced operations – especially electroplating.
The automotive work that has moved into the South has basically
replaced the textile industry. The automotive companies have high
expectations when it comes to computer controls driving the plating
process, process control relating to chemistry, communication and
plating innovation.” Mr. Pazdan and Cliff Roy, company president,
admired the quality strategies of their European and Japanese customers
and decided to pick the best quality strategies from each customer.
It was quite evident that a “canned” quality package would
not work at Roy Metal.
Computer Controls Driving the Plating Process
Beginning in 1997, Roy Metal began to integrate the use of
programmable controllers to run automated plating lines. The next
step was to include the use of computers to interface with the controllers.
The new lines that were installed use bar coding technologies and
touch screen MMI (man machine interface). Some existing lines were
retrofitted with similar computer controls. Roy Metal has “experimented”
with three different interface software manufacturers on different
lines but now has settled into one system that best fits its needs.
Final integration of the plating line computers to the company server
gives management and customers more information. “Plating line
database information is valuable as a management tool as well as to
certify to customers what is being done to their parts.” stated
Mr. Pazdan, “We want everyone in our organization as well as
our customers to have as much information as possible.”
New rack and barrel plating lines at Roy Metal Finishing continue
to be designed, engineered and installed by Roy Metal’s associate
Ken Holcombe and his maintenance staff. A recent addition to the
Roy Metal maintenance team is a systems integrator to oversee the
interface between the computers and the plating line equipment.
As mentioned, Roy Metal has worked with three interface software
systems – two from the US and one from Germany. The company
has since focused on software from Jessup Engineering designed to
provide the flexibility needed to meet the demands of Roy Metal’s
automotive customers. Features such as individual rectifier control,
auto dosing, bar code entry, recipe processing and extensive alarm
system ensure that a part's finish will be consistent regardless
of shift or day they were processed. Having rectifiers on individual
plating cells has allowed Roy Metal to offer automotive customers
repeatability that was not available before. “A rectifier on
every plating tank may be expensive, but it is worth it. It gives
us the flexibility we need to handle smaller lots of parts and the
JIT demands of every industry,” stated Mr. Roy.
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David Elswick, Plating
Specialist, and Ken Holcombe, Plant Engineer, review plating
recipes on the rack alkaline zinc and zinc high nickel alloy
plating line.
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Typically new part numbers are tested using generic plating recipes.
The results are reviewed and a permanent recipe is set up. In normal
production, the operator simply bar code scans the customer part
number, the Roy Metal work order number and quantity (pieces for
rack machines and pounds for barrel machines). The recipe controls
the cleaning cycle, the rectification and the post plate treatment.
As the barrel or flight bar moves through the line, records are
kept for a number of plating parameters for each part number including:
temperatures, exact time in each tank, selected pH readings and
rectifier settings and results (voltage and amperage). All production
data is sent to a central database where it is used in various part
specific and production reports.
Process Controls Relating to Chemistry
The quality engineers from automotive customers want to know
what is controlled and how often is it checked. Roy Metal again relies
on its Access database. All plating lines have lab-testing schedules
set by the Plating Chemistry Manager, Joe Pons. A lab technician records
tank concentrations according to date and time as well as all additions
made to the line. Reports can be run for each plating line that features
a low limit and high limit for each additive, and the actual concentration
is highlighted if out of range and the consumption. A comment area
allows lab technician to provide information about corrective measures
they are or will be taking to return the bath to normal operating
conditions if necessary. Lab results are posted daily at each individual
plating line for supervisor use. The chemistry database information
provides valuable information on consumption and trends in each plating
process.
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The quality department
uses thickness-testing devices throughout the plant. The lab
features a Fischer Technology x-ray as well as the Leica microscope
are used to analyze surface finish and appearance. Atomic absorption
is used for plating tank analysis.
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To analyze the results of sample parts (such as PPAP for a new
automotive part), Roy Metal refers to a plating chemistry report
to give the status of the line when the samples were run and a flight
bar report to show exactly how the parts were processed. This combined
with x-ray thickness reports and salt spray results provides the
automotive customer with a complete quality package.
Communication
Beginning in 2001, Roy Metal offered customers access to customer
specific information through its web site. One of the recurring comments
from customer surveys was that it was difficult to speak with someone
on the phone. So rather than add more staff, Roy Metal began uploading
database information from the company server to its web site. All
orders are tracked throughout the plant using bar codes and the job
status is sent to the Roy Metal web site. Now customers log onto a
“Client Services” section of the web site to see where their
parts are in the plating process. Customers can expedite their orders
as well as print production reports, transportation reports, plating
certifications and copies of invoices. In addition toproviding information
on the web site, customers can also receive e-mail when parts are
approved by the quality department and/or when they have shipped.
Roy Metal has worked closely with x-ray thickness manufacturer Fischer
Technology to send x-ray thickness and alloy percentage information
from the x-ray computer to the company database. This information
is sent to customers via e-mail and stored on the web site.
One of the most successful Roy Metal investments was the design
and implementation of its own intranet communication system. All
associates have access to all quality documents, procedures, engineering
cad drawings, plating specifications, 401K plan, insurance policies,
vacation schedules, lost time hours, machine output, weekly sales
performance and bonuses.
Plating Innovation
Roy Metal realizes the importance of research–especially
in today's world–with the introduction of new hexavalent free
automotive specifications. Cliff Roy’s openness to new ideas
has allowed the company to participate in many research and development
projects. “We have developed a great relationship with all of
our chemical suppliers,” noted Mr. Pazdan. “If they would
like to try a new chemistry on our line, we will work with them. It
provides them the opportunity to collect an incredible amount of data
in a production situation. We can determine if a product will work
in an actual production setting and provide suggestions on how to
make it work if it doesn’t.”
“There is a new collaborative relationship in our industry
between the automotive OEM/supplier, the chemical supplier and the
finisher,” noted Mr. Pazdan. “In the past, customers simply
asked if we could plate to a specific specification. It was a simple
yes or no question. Now, the customer knows much more about what
it is looking for and many of the plating specifications are only
allowing approved applicators. To survive, we have to pursue the
new plating chemistries and the approval process required by the
automotive specifications.”
Recent research and development projects conducted at Roy Metal
have shifted from the high performance trivalents to evolving topcoats.
With much of the chemical research coming out of Europe, Mr. Roy
recently returned from a trip to Spain where he learned more about
the latest developments to meet the EU Directive. “It is important
for Roy Metal Finishing to be on the leading edge of these new plating
chromates and topcoats. In past trips I have always learned a great
deal from the European platers. This trip to Spain was no different.
Our automotive market is made up of a combination of US, European
and Japanese parts suppliers and manufacturers and we need to be
able help them meet the new plating requirements.” stated Mr.
Roy. This type of research is what is behind the latest acid zinc
cobalt and alkaline zinc iron machine using only trivalent chromates.
Company Overview
Zinc Plating is still the backbone of the company. The barrel
and rack machines are recipe driven and have chemistry from Pavco
and Dipsol of America. While barrel and rack zinc still accounts for
a large portion of revenues, more business is being converted to the
zinc alloys that are favored in the automotive industry. The alloys
Roy Metal Finishing offers are: zinc-nickel, zinc-cobalt, zinc-iron
and tin-zinc. The alloy machines are all recipe driven and trivalent
chromates are available for all zinc and zinc alloys.
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New waste treatment
facility designed and built by Roy Metal Finishing associates
ensures that the effluent water quality is acceptable to the
local POTW.
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Roy Metal offers rack and barrel alkaline zinc nickel, 10-15% nickel,
from Atotech
USA. The deposit has excellent thermal and corrosion resistance.
The deposit will consistently pass 250 hours to white rust and 1,000
hours to red rust with a hexavalent or hex-free chromate conversion
coating. Roy Metal’s barrel tin-zinc from Dipsol
of America has excellent solderability and durability, in addition
to high corrosion resistance. Tin zinc is used as an alternative
to cadmium. These two alloys, Mr. Roy suggests, will be the best
of the four alloys long-term. Roy Metal is on the approved Daimler
Chrysler supplier list for the above alloys. Hexavalent-free chromate
post-finishes are available.
Roy Metal continues to offer the more established chromate conversion
coatings, including clear, yellow, black and olive drab. For the
past three years the company has tested a number of the new trivalent
chromates and associated topcoats being introduced as a result of
the European Union End-of-Life Vehicles Directive to eliminate the
use of hexavalent chromium. To date, Roy Metal has four lines to
process thick film passivations on zinc and all the afore mentioned
alloys. It is offering a hexavalent-chromium-free black chromate
that according to Mr. Roy “shows promise but is in the early
stages of production.”
Changing from the hexavalent chromates to trivalent chromates,
or simply adding them to the line is not easy, since totally separate
rinse systems are required for each. The new lines installed over
the past four years have extra tanks and totally segregated rinsing
systems in anticipation of the change in chromates. Another step
in the planning for the elimination of hexavalent chromium involves
new and improved topcoats. New lines also have extra tanks for different
topcoats that will no doubt be important as the use of hexavalent
chromium is eliminated.
Automotive engineers and designers as well as their companies are
also concerned about wastewater treatment. Roy Metal has taken wastewater
treatment seriously since it opened in 1961. In 1998, the company
started reclaiming its oils from the cleaners rather than treating
them in its own waste treatment systems. These oils are transferred
to other companies for reuse.
In 1999, the company started building a new building to house a
completely new waste treatment system. The Roy Metal team started
with years of chemistry data, mechanical data and associate suggestions
and engineered a complete waste treatment system. The new125,000
gal/day waste treatment facility came online February 2001. Some
of the accomplishments include a self containing building for any
tank ruptures or spills, reduction in chemical use, 30% recycling,
computer and controller interface, the system constantly reviews
parameters set and constant influent flow. The system will run by
itself, warn associates of extreme conditions, and if no action
is taken will shut itself down and the incoming water supply to
Roy Metal. Roy Metal’s dedication to wastewater treatment has
earned it the Compliance Excellency Award from the local POTW, Western
Carolina Regional Sewer Authority three years in a row.
The Quality and Environmental Management Systems at Roy Metal were
completely restructured in 2003. After originally receiving ISO
9002:1994 certification in 1997 and ISO 14001:1996 in 2000, the
management team decided to give the system a new look and combined
both systems into a new Management System. The new system is stored
on the company intranet so all employees can have quick access to
all information. The upgrade was successfully audited to ISO 9000:2000
in May 2003. Future plans are pointing toward ISO/TS 16494:2002
certification in December 2003.
Company Outlook
“I don’t think progressive platers will go out of
business, even though there will be less manufacturing in the United
States,” concluded Mr. Pazdan. “The manufacturers that do
remain will have very high expectations of the platers. I also believe
the chemical suppliers will have to be more selective about who they
sell the product to because the parts that are plated in the United
States will be high precision parts, automotive safety items or other
critical mechanisms.”
“Yearly, we reinvest back into the company to promote opportunities
for potential business. Today, we can process parts with flexibility
and certainty that all customer and Roy Metal parameters are satisfied
for a lot, work order, barrel or flight bar. We are into alloys
and trivalent chromates. So far, we have been successful maintaining
our position in this business environment. But we need help from
our government leaders to protect our manufacturing here in the
USA. You can have all the bells and whistles but if manufacturing
continues to move to Mexico or China then we have a big problem.
All we want is a level playing field so we can continue our commitment
to our associates, customers and to our local community.” says
Mr. Roy.
“We’ve been making it happen for years and we are committed
to the future,” Mr. Roy said proudly.
