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: email@example.com 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?