CTMA Project #: 140384
Problem:
- Depot maintenance cycle time has become a high profile issue. Long cycle times adversely affect weapon system and spare parts availability.
- Hard chrome plating processes create bottlenecks at depots, limiting throughout and lengthening cycle time.
- Intricate masking processes and hand grinding requirements are labor intensive and put high demands on skilled craftsmen.
Benefit:
- Availability: 200% increase in plating equipment capacity; resulted in weapon systems out the door faster.
- Cost Savings: Annual labor savings of $1.1M; 83% decreased labor cost/part.
- Reliability: Improved process control resulted in significant rework reduction; 17% on one part & 46% on another.
- Cycle Time: Reduced individual part turnaround by an average of 60%; production capable of meeting demand – previously impossible!
- Safety: Worker exposure to hexavalent chromium vapors reduced 50%.
Solution/Approach:
- A new approach to anode design avoids the needs for masking, while creating plating conditions that optimize current density and electrolyte flow for each individual part.
- Specialized tooling and rack fixtures were installed on critical parts.
- The new tooling resulted in:
- Reduced labor for masking
- Faster plating times
- More uniform chromium deposits.
DOD Participation:
- U.S. Air Force (Oklahoma City Air Logistics Center)
- U.S. Army (Corpus Christi Army Depot)
- U.S. Navy (Fleet Readiness Center Southwest)
Industry Participation:
- Advanced Tooling Corporation
- NCMS
