12 Proven Tips to Save Your Time & Money for Aluminum Anodizing, Hardcoat, and Other Metal

Finishing Services

2014 Guide

© 2014 Katahdin Industries Inc.

Tip 1: Upgrade Packaging

Invest in re-usable plastic shipping & packaging containers:

Less Waste Adopt: Re-usable plastic packaging. Normal pays back after 10 shipment vs. single use containers and more quickly if parts are damaged.

Avoid: Paper, cardboard & bubble wrap and hand wrapping

Better Quality Eliminate rework and/or scrap due to • Part on Part contact• Metal ties on part contact• Damage due to excessive part movement and/or incomplete part protection• Contamination & moisture

Increased Labor Efficiency Adopt: Reduce time to pack & unpack parts

Re-usable Shipping Containers

Part Sized Inserts Plastic Bins

Tip 1: Upgrade Packaging

Savings Factors

Direct Cost Savings• Packaging materials: usage/wastage/storage• Damage to parts in transit: scrap & rework cost• Labor costs: Time to wrap/unwrap• Transportation cost: Less than optimal pack density

Indirect Savings• Lower inventory (eliminate safety / make up stock)

Tip 1: Upgrade Packaging

Resources: http://www.amatechinc.com/services/calculator

Advantages & Disadvantages

<<< Cardboard / Single Use Plastic/Multiple Use>>>

Advantages• Initially inexpensive• Lightweight• Ideal for non-returnable

applications, i.e., exports• Recyclable

Disadvantages• Cost of collection and disposal• Have to purchase in bulk• Storage• Limited protection• Time consuming to assemble• Staples, splinters can damage contents• Not weatherproof

Advantages• After initial payback, more cost effective• Longevity• Constant Tare• Purchase or Rental as required• Secure stacking in storage and transit• Nests/folds for storage• Better protection of contents• Operator comfort and safety• Traceability• Weatherproof• Non-absorbtion of contaminants• Cleanable• Recyclable

Disadvantages• Initially expensive• Weight• Cost, if not returned

Tip 2: Straighten out the Paperwork

4 Steps to faster turnaround and better quality

Better Quality Eliminate rework and/or scrap due to • Jobs improperly run

Increased Labor Efficiency Engineering and contract review can start immediately.

Faster Turn Times Jobs get to production – and back to the customer - more quickly.

1

Email / Fax copy of

Purchase

Order

2

Include original

paperwork with the

order. Place all

documents in clear

plastic pouch on top

of parts in sealed box.

3

Include all paperwork

with order:• Purchase Order• Shipping

Docs• Print for each part

4

For each part, include: • Surface Area• Alloy• Part # or Unique ID• Clear Masking

instructions• Exact Finishing

Instructions• Where / where not to

rack• Color sample (if color

match required)

Tip 2: Straighten out the Paperwork

Email / Fax Copy of Paperwork

• Start order entry while materials are in transit.• ID issues earlier to resolve w/o delay

Original Paperworkwith Order

• Identification and traceability during receiving• Plastic pouch protects documents

Include all paperwork

• Faster Contract & Engineering Review

The goal is to get the parts into production as quickly as possible without risking poor quality.

Tip 2: Straighten out the Paperwork

Complete information allows for faster contract and engineering reviews and eliminates many causes of poor quality.

Information Explanation

Alloy • Different alloys process differently and will impact coating build rate, oxide color, hardness, dielectric properties, and risk of burning.

Surface area of part • For accurate and consistent coating thickness. Processing requires calculationof total surface area to run the job – starts with the total surface area of one part. If you have a print, you most likely can quickly calculate surface area.

Incoming Dimensions • For hardcoat, communicate dimensions for critical areas to allow calculation of metal removal for cleaning and cosmetics before coating build. Show on print.

Unique Part Number • Traceability and accurate recall of process steps and price.

Racking Location • Avoid guesses of where / where not to rack. Show on print.

Clear Masking Instructions

• Faster Contract review. Show masking locations on print.

Clear Processing Instructions

• Best success is achieved by detailed and non-conflicting finishing instructions.Be clear on expectations such as gloss or matt finish.

Color • Provide high and low color samples when color match is important. PMS charts, paper color, paint chips or similar are poor options unless nothing else exists.

Tip 3: Control the Aluminum Alloy

Issue Explanation

Never Mix Alloys Different alloys process differently given the various constituent alloying metals in aluminum.• Different coating build rate.• Different conductivity of metal• Different inclusions of alloying elements in coating

Mixing allows can lead to:• Color and surface appearance variations• Different quality of oxide: hardness, corrosion resistance, dielectric, and

propensity to crazing.• Burning of parts due to different conductivity levels of alloys• High coating thickness variations

Single Source Same Alloys

Different smelters may have the same specification but produce slightly different products. All of the same impacts as above, but to a lesser degree.

Better Quality The same alloy and same supplier will reduce process variations leading to poor quality.

Faster Turn Times No need to put jobs on hold and work through a disposition and/or rework.

Tip 4: Work Out a Schedule

• Achieve a balanced work flow with your supplier• Constant speed beats fast / slow every time.

Increased Labor Efficiency Labor, materials, and process time can be scheduled to avoid unnecessary queue time.

Faster Turn Times Jobs get to production – and back to the customer - more quickly. Reduces risk of disorganization and mistakes.

Tip 5: Establish a Standard Order Size

Single order sized optimized around anodic coating process• Normally surface area is limited by size/capacity of the process tank. • Overall dimensions of parts may be critical• Other tanks may impose limitation as well (pre-process, dye, etc.).

Work with your metal finisher to agree optimal load sizes and package accordingly.

Reduce set up times by having a complete process standard & avoid changing run conditions

Better Quality Standard orders can be optimized. Racking can be optimized. Process conditions can be standardized.

Faster Turn Times No requirement for engineering and contract review if the order stays the same. Can get to production more quickly.

Tip 6: Invest in Custom Titanium Tooling

Titanium Racking:• Racks last many years and hundreds of runs• No need to strip between uses• Design rack to:

• Optimize load sizes• Prevent damage to parts• Allow for optimal draining / rinsing

• Master frame and spline racks can be used with racking machines for higher productivity

*See blog post….+

Less Waste Titanium racks do not wear out and do not need to be replaced.

Better Quality Eliminate rework and/or scrap by better drainage and rinsing

Increased Labor Efficiency Adopt: Reduce time to pack & unpack parts

Tip 7: Eliminate Contamination

Factor Risk Item Possible Sources Impact

Contaminants Adhesives

Excessive Oils

Protective films, bonding agents, etc.

Machining and tooling oils

Missing coating

Metal Shavings & Burrs

Other metals

Left over from machining, etc.

Cross contamination from bead blasting media

Burn marks / bare spots

Burn marks

Wet Parts Water / Moisture Poor packaging, storage, and/or transportation

Corrosion & staining

Better Quality Eliminates need for disposition during receiving.Parts can follow job standard process without special steps.Eliminates major cause of poor quality.

Reduced Lead Time Eliminate extra processing steps and incidence of rework.

Tip 3: Eliminate Contamination

Oils & Shavings Adhesives left from protective wrap

Moisture

Tip 8: Reduce # of Approved Suppliers

Choose a supplier(s) who has/have the best fit with your organization’s needs based on:• Their anodizing expertise and ability to solve problems. Often one needs to get beyond how the

part looks to understand what can be accomplished.• Their understanding of your business needs.• The quality / timeliness of the suppliers communication with you.• Your size & the sense of priority you think you can / do have.• Their service level (i.e., turn times, pick up / drop off services, etc.).• Their overall defect rate (rework and SCARS) and their work with you to reduce defects

and lower rework and scrap costs.• The completeness of their product offering to meet your overall manufacturing needs.• Their risk profile in respect to organization depth, upkeep of facilities and equipment, and systems.• Whether they have value added and proprietary services that help you upsell your

products or reduce overall costs. • Whether they have a certified QMS through a respected accrediting organization.

Better Quality Eliminates variance between suppliers.Improves communication by eliminating duplication of instructions and special needs.….

Increased Labor Efficiency ….

Tip 9: Reduce Usage of Expedited Services

Too often, the expected price for running the job is lost when premiumservices are employed to meet schedule – either by rushing jobs or by using more expensive shipping options such as overnight delivery.

These services can be reduced and often eliminated.

Start by reviewing your shipping costs to see how much you are spending on premium services. If after following all the recommendations you still require the use of such services, try to arrange for a volume discount.

Reduce Cost Avoid: Use of Fed Ex Overnight and UPS Red services.

Tip 10: Establish Contact Sheets

Be clear on whom the supplier should contact for:- Contract Review issues- Quality concerns- Shipping- Payment

Provide Name, Title, Phone, and email!

Increased Labor Efficiency Adopt: Streamlined communication

…and then ask the supplier for the same.

Tip 11: Negotiate Payment Terms

Negotiate early payment discounts.

Your metal finishers main cost is labor that is paid weekly with the other coststypically net 30. Therefore, most companies will agree to an early payment discountssuch as 2%/10 Days.

Reduce Cost Depending on payment terms, early payment discounts can reduce prices by 1 – 3%

Increased Labor Efficiency No need to make payment calls.

Tip 12: Combine Value Added Services

Choose a finisher who can provide additional services to eliminate unnecessary handling while reducing costs and complexity.

• Proprietary metal finishing technologies that solve design and engineeringchallenges

• Printing & laser engraving• Light assembly

Less Waste Reduce unnecessary transport & handling and associated lead times.

Better Quality Clearer accountability.

Summary

• Changes can result in significant cost savings and reductions in turn time.

• Improvements are sustainable, proven, and win-win.

• Deepens the relationship and trust with your supplier.

Continuous Improvement Action Plan

• Work with your supplier on a balanced score card for key operating metrics such as OTD, Turn Times, Defects in Process / Rework, Paperwork Errors, DSO and SCARs,. Use prior six months as baseline to track improvements and impact of initiatives.

• Identify and work on one or two initiatives maximum at a time.

• Complete the initiative, assess the impact, identify areas of further improvement before starting the next one.