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Scrap Generation in Hard Chrome Plating
We do hard chrome plating on motorcycle front fork inner tubes and shock absorber piston rods. We plate 6,00,000 to 7,00,000 pieces per month.
Even after reworking rejections, about 0.9% pieces finally get scrapped as it is no more viable to plate them.
1. How's the percentage of scrap generation in your companies.
2. How have you controlled this in your systems.
3. Does automation help in reduction of scrap.
4. What is the most economical way to utilize this scrap.
MEGACOAT - INDIA
2002
A. If you're rejecting 6000 to 7000 with reject rates possibly double that in one month, then you need some help. If I were you, I would try reducing the reject rate through DOE.
Steve Delaney- Beamsville, Ontario
2002
A. OK, you have a problem. Precisely what is the cause of the problem, adhesion, skip plate, too little chrome , too much, irregular plate, bad grinding, burned grinding , or which of dozens of other possibilities is it.
James Watts- Navarre, Florida
2002
Q. The scrap is generated primarily due to grinding defects and handling damages which have to be ground again and have to be plated for higher thicknesses. Scrap due to plating defects after replating is negligible.What percentage of scrap gets generated at your end due to plating defects and what is it due to other defects.
Rahul Nigam [returning]- India
2002
A. Most grinding and mishandling problems start with management! Pushing for higher productivity forces help to cut corners which leads to rejects. Proper training and grinding equipment is a start. The proper grinding wheel for each operation is mandatory. Proper feeds and speeds is mandatory. Appropriate containers and or covers is a given. Since it takes about 4 times as long to QC, reroute, grind and replate, it would be appropriate to go a little slower and cut down rejects and still make more profit. A very well qualified consultant could save you a lot of money in a one year time frame.
James Watts- Navarre, Florida
2002
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