1. 2016 Maintenance Innovation Challenge
Advanced Metal Finishing Facility to improve electroplating
PROBLEM STATEMENT
Electroplating exposes workers to chemicals hazardous to their health such as caustic acids, cyanide, heavy metals and other carcinogens.
Chemical additions to tanks and hoisting parts are done manually, exposing the worker to physical strain.
Electroplating processes produce air emissions which are hazardous to the environment.
Evaporation of waste water and chemicals reduce efficiency
Quality and consistency of plating is difficult to control due to human error/deviations.
Need for increased capacity for C-17 and C-5 parts.
BENEFITS
The layout and automation of electroplating process lines will significantly limit worker exposure to hazardous materials.
Automated system for chemical additions and adaptable overhead crane system will reduce physical strain and chemical exposure.
Improved air scrubbers will reduce air emissions. Improved ventilation will enhance air quality for workers.
Chemical evaporation and drag-out will be reduced at the source to improve efficiency.
Automated processes and testing will improve quality and consistency of finishing.
Increased size will allow processing of bigger parts.
TECHNOLOGY SOLUTION
Prep area is separated from wet process area, removing the worker from the hazardous environment.
9 Automated process lines controlled by programmable logic controllers (PLC) allow operators to run the process from the prep area.
Approved process recipes are saved to the PLC to improve quality and consistency of plating.
Relocation of quality lab to AMFF and automated tank testing allows for more efficient testing and analysis.
Automated chemical additions and tank shields provide further protection to the worker.
Installation of large tanks to have capacity for larger parts.
GRAPHICS
Isolated prep area with hoist
Automated process line
Programmable logic controller
Process lines with tank shields