SEA DV – ENGINEERING MEETING

4 October 2018
SBM
Electroplating (EP)
Topic :
 EP Precise Chemical Control 2H18
 SPC project 2018 (ZNC & ZDT)

PID EP
Josephine
 Process Optimization 2017 vs 2018
Individual Monitoring Process
Current (1H18) : Plan (2H18) : Target (2H18) :
Baseline Optimization Analysis
$/dm2 per item
• Nickel Metal
Measure Nickel Metal ($/dm2) Chemical per process • Pre Treatment Process ($/dm2)
Pre treatment • Nickel Plating Process ($/dm2)
•Satin Bath Nickel Salt
Measure of Satin Plating as a ($/dm2) • WWTP Line ($/dm2)
 Waste Water Treatment
•Chrome plating ($/dm2)
•Common Chemical Chrome Plating
Others • Others chemical ($/dm2)
Monitoring as a total of consumption($/dm2)

Summary Sub material precise control consume ($/dm2)

Precise Control by Process

Optimization ($/dm2)
 EP Precise Chemical Control Plan 2H18
Optimize • Review Voltage & Ampere
Process
Parameter

Plan Lab
• Checking Method
2H18 Method

• Filter Tank Leaking

Reduce
Chemical waste • Chemical Level monitoring
(equipment
leaking)

• Setting up for CPS system in Monitoring

In Central
Procurement Sub- Material
Progress Store

Baseline :

Baseline :
 EP Precise Chemical Control 2H18
Objectives with CPS System :
To Eliminate To Improved
•To enhance production traceability thru real time data
•Paper based Manual – Data recorded
•To enhance process control thru SPC monitoring
•Manual checking quantity
•Transparency of reporting
•Manual mixing ratio
•Data accurate based on actual running
•Manual calculate excel chemical concentrate checking
•Able to trace back the history on in and out stock
•Stop production due to chemical / part shortage
•Zero stop production
•Abnormal used monitoring
•Zero special cost for special delivery
•Excel manual calculation
•Chemical recording and monitoring by system
CPS System 3 phase :
2. Topping Up
1. In-Out Balance 3. Analyze consumption (gr/dm2)
(weighing)

Full Reporting Access

Digitalization and Automatic reporting

 EP Precise Chemical Control Plan 2H18
2017 2018

Cost/dm2

2017
• Sub material control thru process optimization
• Controlling of consumption based on total of
consumption
2018
• Individual monitoring process (improvement)
• Controlling of consumption based on every process
consumption (Nickel-Nickel Plating, Nickel Satin Plating,
Nickel Satin Chrome Plating, Nickel Chrome Plating)
EP Precise Chemical Control Plan 2H18
Sub-Material high due to
rework CSHG201 gear
high NC

NC contaminated issue
worse happen in big surface
(0.9 dm2- 1.15 dm2 )
 CSHG201 Gear Contaminated Issue
Flow of Current Distribution
Action Plan :
1. Add 1 more anode titanium basket to increase Ampere in Satin Nickel tank become > 600 A
2. Add chemical addition (Nimac 8123) to prevent metallic impurities in Satin Nickel Tank
3. Maintain pH in dewatering tank must to > 10
4. Add chemical (chromic acid + H2SO4) in rinse tank to clearing the surface.

1 1 3 3
Standard Current Distribution for Nickel Plating > 4 A/dm2

2 After Satin tank 4

 EP Precise Chemical Control Plan 2H18

Ni Metal = Baseline-Result/Tot dm2*1000

Common Chemical = Baseline – Result * Tot dm2
SEA DV – ENGINEERING MEETING
4 October 2018
SBM
Electroplating (EP)
Topic :
 EP Precise Chemical Control 2H18
 SPC project 2018 (ZNC & ZDT)

PID EP
Josephine
 EP Integration of System for Process & Equipment Monitoring

Chrome Pre- Nickel

Plating Bath Treatment Plating Bath
Volt/Amper Volt/Amper Volt/Amper

Temp (oC) Temp (oC) Temp (oC)

Process Monitoring
(2017-1H18)
Chemical ratio Chemical Chemical

Throwing power Oil Brightness

Contamination
PH

Temperature

Machine Condition

Equipment Level Water Length of Chain Hydraulic

Filter tank
Monitoring Chemical Tank (up&down) Motor
2H18

Boiler Water Air Blower

Rectifier Sand Filter
Quality
Yellowish issue due to ampere drop (17/07/2018):
Volt - Ampere Chrome Tank Monitoring
Finding Root Cause of Ampere Drop & Action Plan
Define Action Plan

Found there’s a gap between hanger’s copper Action plan to this case is re adjust cooper bar
block and copper bar at certain hanger ,that’s screw to make the spring more loose.
make supply current no good.
 Control and Monitoring system for EP Chemical Overflow
• Chemical solution was overflow 5 times due to lack of monitoring
• This system will install eliminate human operation error
Chemical consumption 1H2017 :
Item Jan'17 Feb'17 Mar'17 Apr'17 May'17
Sales $ 205,570.0 $ 287,038 $ 292,167 $ 243,214 $ 277,655
$ 6,896 $ 20,480
$ 3,739.2 $ 2,156 $ 5,476.8
Ni Salt (Over : 2,000) (Over $13,000)
$ 5,055 $ 6,082.5
$ 3,042.5 $ 3,975 $ 2,415
Alkaline Cleaner (Over : 1,000) (Over : 2,000)
$ 7,525
Satin Chemical $ 2,805.0 $ 2,115 $ 2,070 $ 2,115
(Over : 4,000)

Concept of Chemical Overflow

Preventive System
 Control and Monitoring system for EP Chemical Overflow

Probe Position

Lamp Indicator

Material of Probe :
Titanium
Probe
 EP SPC - M Filter Chemical Solution Sensing - Phase 2
Baseline :
EP Filter Tank • 3 Filter Tank Broke down due to leaking
• 3 Case Downtime happen since February.
• Rough Surface LNC 0,5 %
• High TOC 6509.6 ppm on Chemical Solution
• High Sub material Consumption due to earlier carbon
treatment
Target :
• To achieve Zero Downtime of Machine
• Auto-Stop for Motor Pump to prevent leaking
• Monitor & analyze equipment for predict machine
condition (Pressure Sensor)
• Performance the Pre-preventive maintenance.
• Increase Quality of Nickel Solution
Pressure
• Rough Surface LNC 0%
chart
 Front Process EQUIPMENT MONITORING DASHBOARD
TOWARDS ZERO COPQ DEPARTMENT

Rectifier Alarm Record

Integration

Filter Tank Sand Filter

Chiller Hydraulic Unit
 Towards Zero COPQ Department
Thru SPC & Real Time Data Monitoring :

Objective:
1. Process Stability (thru SPC ZNC ZDT) and Improve Quality

Line NC : < 0.1%

Target: Towards Zero COPQ

Line NC : 1.39%
2018
Line NC : 2.29% 2017
2016
Towards Zero COPQ Department
Thank You!