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DMI DIE PLATING

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					DMI DIE PLATING CASE STUDIES
                                    DMI (UK)
                        West Chirton Ind. Est.
                               Gloucester Road
                                 North Shields
                                 Tyne & Wear
                                    NE29 8RQ
                                      England
                          Tel: 0(191) 2575577
                          Fax: 0(191) 2581525
                    e-mail: sales@dmiuk.co.uk
                       web: www.dmiuk.co.uk
   DMI offer a world-wide service
1970   Koka Chrome Industries of Japan develop the process
1989   DMI (UK) introduce the process into the UK
1992   DMI expand it’s facilities into continental Europe
              DMI (Europe), Holland
              Tecnocrom, Spain
1996   DMI expand it’s facilities into Australia and North America
              Hard Chrome Industries, Australia
              DMI Automotive, the USA
2002   The process is introduced into South Korea and Mexico
              Seo Kwang Industry, South Korea
              DMIA Mexico
2003   The process is introduced into Brazil
              Cascadura, Brazil
                    DMI (UK)
             DMI
          AUTOMOTIVE     DMI (EUROPE)
                       TECNOCROM            SEO
                                           KWANG
                                                KOKA CHROME
       DMIA
      MEXICO




               CASCADURA
                 BRAZIL

                                             HARDCHROME


DMI continue to develop the process to meet changing demands
   Advantages of using the process
The DMI process of hard chroming plating of press dies
offers significant savings in time, operational efficiency
and costs.
Reduced new die costs            Reduced press down time
Improved panel quality           Reduced scrap rate
Reduced pimpling and scoring Reduced panel rework
Reduced die maintenance          Reduced oil usage
Anti wear                        Consistent die surface
        Case Study 1
GKN Sankey Floor pan
Annual savings of £200,000 were achieved by the hard chrome plating one die set
Background.
*             This panel is produced by GKN Sankey of Telford, England.
*             The current requirement is for more than 100,000 parts per year.
*             The tool was chrome plated by DMI (UK) in September 1994 and has produced more than 460,000 parts since then. (to end
              Dec. 1998)
*             The chrome layer is still intact and does not show any significant wear.

History prior to chrome plating.
*             Draw related problems resulted in splitting, scoring, etc. The subsequent scrap rate was as high as 30%.
*             Heavy draw oil application was necessary to produce a panel of acceptable quality.
*             This resulted in environmental and handling problems.
*             The annual cost of draw oil alone for this one part was £12,000.
*             The customer required that the parts be degreased prior to receipt.
*             This resulted in an additional degreasing operation, environmental and disposal problems and significant additional costs.
*             The operators were required to prebend each blank before manually feeding it into the press to avoid splitting.
*             Acceptable panels could only be produced when the press was run by skilled and experienced operators.
*             The materials suppliers were continually on site discussing material problems and attempting to find solutions to the
              problems.
*             Because of these problems, production rates were very low.
*             It was necessary to run the tool continually in the press line in an attempt to meet the customers production requirements.
        Case Study 1
Performance following chrome plating.
*            The part is now very easy to produce.
*            Draw related problems have been almost eliminated. Draw related scrap has been reduced to zero.
*            The heavy draw oil has been replaced with D. A. Stuart's 1050E soluble (water based) oil applied by a spray unit. This is
             more environmentally acceptable and has significantly reduced environmental and handling problems and costs.
*            The annual cost of oil has been reduced to £1,200 representing a 90% saving.
*            The additional degreasing operation and environmental and disposal problems have been eliminated.
*            The prebend is no longer required.
*            Acceptable panels are now produced by any operator.
*            The material suppliers are not now required on site.
*            The chrome plating alone has allowed the production rate to increase by 50%.
*            Chrome plating has allowed other improvements to be made to the press line which has resulted in a doubling of the
             production rate.
*            The tool is still run almost continually to meet the customer’s increased demand. The ease of operating this tool due to the
             chrome plating make it an excellent stand by job.

Additional benefits.
*            The improved forming after chrome plating, has made it possible to make a reduction in the blank size resulting in
             significant material cost savings.
*            Elimination of the requirement to prebend the blanks before the draw operation, has permitted the installation of a blank
             feeder with the subsequent reduction of operators on the draw tool from 4 to 1.
*            Due to these improvements, GKN Sankey have been able to significantly improve the quality and condition of the panels
             and the quality and reliability of the service to their customer.

Annual savings of £200,000 were achieved by the hard chrome plating one die set
       Case Study 2
Ogihara Europe        Reinf. Tunnel
Before chroming       Press speed 170 panels per hour
                      Press down time 50%
Press time of 16 hours was required to produce 1400 parts
After chroming        Press speed 229 panels per hour
                      Press down time 0%
Press time of 6 hours was required to produce 1400 parts
i.e.    An additional 10 hours of press production time was made
        available
       Case Study 3
Seat    5 die sets
        Draw related press down time was monitored and recorded
        for a period of three months prior to chrome plating
        The same criteria were then used to record draw related press
        down time for the same period after chrome plating


        As a direct result of chrome plating, draw related press down
        time was reduced by 282 hours (down from 326 to 44 hours)

i.e.    An additional 282 hours of press production time was made
        available
                    DRAW RELATED PRESS DOWN TIME


    100

        90                                                          BEFORE CHROME
                                                                    AFTER CHROME
        80

        70

        60
Hours




        50

        40

        30

        20

        10

        0
             Roof    B Pillar   Front Door Inner Front Door Inner    Front Fender
                                                                         Inner
  A Question

The operational and cost advantages of using
 the DMI process are significant, clear and
             well documented


So why do customers experience difficulties
        in scheduling die plating?
    Cost
The problem is that much of the costs of not chroming are internal
and can be absorbed or ignored or swept under the carpet. The cost
of chrome plating is an external cost which must be justified.
Authorisation is required to spend the money. Someone has to raise a
requisition, someone has to sign an order and someone has to pay an
invoice.
As has been demonstrated, the cost savings offered by the chrome
plating of press dies far outweigh the costs of chrome plating and
cost should not therefore be an issue which discourages chrome
plating. Rather, it should be an issue which encourages chrome
plating.
    Time
Time
Normal turn round at DMI is 48 - 72 hours
With proper planning, turn round of less than 48 hours is possible
DMI are developing methods of even faster turn round such as using
a previously supplied shell as a template for the manufacture of the
plating anode


With better planning and communication between DMI and it’s
customers, turn round of less than 36 hours can be achieved
    Personnel Resources
Personnel Resources


Customers often do not have the resources to sent as many dies as
they would like or to send dies when they would like


Resources which would be better spent planning chrome plating are
then used to rectify problems such as pimpling, to maintain the
surface condition of the dies, to discuss material variations with the
material suppliers, etc., etc.

  PREVENTION IS BETTER THAN CURE
What can you as a customer do to allow
 for better planned and more efficient
           chrome plating?


What can we as a supplier do to help?

				
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Description: DMI DIE PLATING