1. RACK DESIGN and MAINTENANCE Don Bauer Associated Rack Corporation Chicago, IL

2. Introduction Equipment Manufacturers Dimensional Restrictions Weight Restrictions Part Presentation and Spacing Rack Material Manufacturing Techniques Auxiliary Anodes, Robbers, and Shields Optimized Designs Maintenance Selecting a Supplier

3. Rack Anatomy Hooks Spline Cross Bar Tips

4. Equipment Manufacturers Automatic - Hoist - Return Manual

5. Dimensional Restrictions Overall Height Width Depth Top of Part T.O.P. O.H. W

6. Weight Restrictions Machine Capabilities - Limits of the Hoist and Structure Operator Capabilities - Operator Limits and OSHA

7. Part Presentation Proper Presentation to Allow Maximum Exposure Proper Presentation to Allow Minimum Shading

8. Part Presentation (cont.) Position Parts to Minimize Solution Dragout Position Parts to Minimize Air Pockets U U U

9. Rack Material

11. Manufacturing Techniques Construction Soldering Replaceable tip Design

12. Auxiliary Anodes, Robbers, and Shields Auxiliary Anodes +-+-

13. Auxiliary Anodes, Robbers, and Shields Robbers

14. Auxiliary Anodes, Robbers, and Shields Robbers Cathode

15. Auxiliary Anodes, Robbers, and Shields Shields

16. Auxiliary Anodes, Robbers, and Shields Shields

17. Auxiliary Anodes, Robbers, and Shields Shields

18. Auxiliary Anodes, Robbers, and Shields Shields/Mask

19. Optimized Design Do Not Need a Rack for Each Part Gather all Parts to be Finished Identify Racking Location Separate into Groups with Similar Racking Locations Separate into Similar Size Groups Design Tips to Hold Different Parts on one Rack

20. Ergonomics Lifting Restraints Minimize Squeeze Tips if Possible Use Thin Gage Material if Squeeze Tips are Required Rotate Workers

21. Maintenance Do Your Rack Manufacturer a Favor Proper Storage Budget for Method of Storage Keep Rack Capacity 100%

22. Selecting a Supplier Look for a Company with a History of Successful Performance Be Sure your Supplier Knows Your Process and Metal Finishing in General

23. Conclusion “ The Right Start to a Perfect Finish ”