Transforming Metal Finishing Processes at Aerospace Manufacturing, Overhaul

and Repair Installations

Transforming Metal Finishing ProcessesTransforming Metal Finishing Processes at Aerospace Manufacturing, Overhaulat Aerospace Manufacturing, Overhaul

and Repair Installationsand Repair Installations

ASM InternationalSeattle, WA

May 16, 2006

Peter Gallerani, MSF/AESF Fellow Kevin L. Klink P.E.

ASM InternationalASM InternationalSeattle, WA

May 16, 2006

Peter Gallerani, MSF/AESF Fellow Kevin L. Klink P.E.

Metal Finishing Industry StatusMetal Finishing Industry StatusMetal Finishing Industry Status

During the past decade significant economic, regulatory, and technology factors have influenced the metal finishing industry, resulting in some major changes in where and how metal finishing processes are performed…

During the past decade significant During the past decade significant economic, regulatory, and technology economic, regulatory, and technology factors have influenced the metal factors have influenced the metal finishing industry, resulting in some finishing industry, resulting in some major changes in where and how metal major changes in where and how metal finishing processes are performedfinishing processes are performed……

Presentation OverviewPresentation OverviewPresentation Overview

• Transformation and Trends in Metal Finishing• A Few Process Improvement Considerations• Mapping and Modeling • Information and Control Systems• Successful Process Transformation

• Transformation and Trends in Metal Finishing• A Few Process Improvement Considerations• Mapping and Modeling • Information and Control Systems• Successful Process Transformation

TransformationTransformationTransformation

• What is it?– Latin, transforma: trans (change) + formae

(form) – A major change in form, nature, or function

• Why is it needed?– To help cope with a new, more challenging

marketplace

• What is it?– Latin, transforma: trans (change) + formae

(form)– A major change in form, nature, or function

• Why is it needed?– To help cope with a new, more challenging

marketplace

Target Benefits for New Systems/Technologies Include

Target Benefits for New Target Benefits for New Systems/Technologies IncludeSystems/Technologies Include

• Improve part durability/quality• Improve operability and maintainability• Reduce use of toxic chemicals and waste generation• Reduce manufacturing and rework cycle times• Maximize product yield & reduce resource

consumption (efficiency) • Provide flexibility for changing workload• Reduce life cycle costs/increase net profits• More sustainable

• Improve part durability/quality• Improve operability and maintainability• Reduce use of toxic chemicals and waste generation• Reduce manufacturing and rework cycle times• Maximize product yield & reduce resource

consumption (efficiency)• Provide flexibility for changing workload• Reduce life cycle costs/increase net profits• More sustainable

Nine Key Metal Finishing Technology Trends (2005/2006 NCMS Survey)

Nine Key Metal Finishing Technology Nine Key Metal Finishing Technology Trends (2005/2006 NCMS Survey) Trends (2005/2006 NCMS Survey)

1) Change to “greener” process chemistries2) Change from “wet” process to “dry” process3) Optimize conventional wet processes to achieve near zero

discharge and risk 4) Change material from finished metals to non-metals5) New metal alloys6) Improve process monitoring and control systems (including

automation) 7) Develop/deploy nanotechnology8) Pursue sustainable manufacturing9) Improve energy efficiency

1) Change to “greener” process chemistries2) Change from “wet” process to “dry” process3) Optimize conventional wet processes to achieve near zero

discharge and risk4) Change material from finished metals to non-metals5) New metal alloys6) Improve process monitoring and control systems (including

automation)7) Develop/deploy nanotechnology8) Pursue sustainable manufacturing9) Improve energy efficiency

NCMS Survey CommentsNCMS Survey CommentsNCMS Survey Comments

• Some significant manufacturing process changes already, R&D and implementation of replacement processes will increase after 5 years and continue over the next 20 years

• Decreasing but still widespread use of conventional metal finishing wet processes that will still be around for 20 years + (noted substantial opportunities for cost-effective process improvement available, but underutilized)

• Drivers (combined for all nine trends)– Cost (63%)– Technology (43%)– Regulatory (34%)

• Some significant manufacturing process changes already, R&D and implementation of replacement processes will increase after 5 years and continue over the next 20 years

• Decreasing but still widespread use of conventional metal finishing wet processes that will still be around for 20 years + (noted substantial opportunities for cost-effective process improvement available, but underutilized)

• Drivers (combined for all nine trends)– Cost (63%)– Technology (43%)– Regulatory (34%)

Selected Process Improvement Opportunities

Selected Process Improvement Selected Process Improvement OpportunitiesOpportunities

Process WaterProcess Water Observation IObservation I Observation IIObservation II

City WaterCity Water ImmediateImmediatestainingstaining

Very roughVery roughsurfacesurface

Soft Water,Soft Water,TDS > 200 ppmTDS > 200 ppm

Slow stainingSlow staining RoughRoughsurfacesurface

DI Water,DI Water,TDS < 200 ppmTDS < 200 ppm

Very slowVery slowstainingstaining

ContaminatedContaminatedsurfacesurface

DI Water,DI Water,TDS < 100 ppmTDS < 100 ppm

No stainingNo stainingobservedobserved

SmoothSmoothsurfacesurface

DI Water,DI Water,TDS < 10 ppmTDS < 10 ppm

No stainingNo stainingafter 1 hourafter 1 hour

Bright & shinyBright & shinysurfacesurface

A-Water Quality Improvement Tests AA--Water Quality Water Quality

Improvement TestsImprovement Tests

B- Impact of Measured Errors on Process Control Ranges at Aerospace OHR Facility BB-- Impact of Measured Errors on Process Impact of Measured Errors on Process

Control Ranges at Aerospace OHR FacilityControl Ranges at Aerospace OHR Facility

C - Process Solution and Rinsewater Purification/Recycling can Provide Significant

Chemical, Water, Energy and Cost Savings

C C -- Process Solution and Rinsewater Process Solution and Rinsewater Purification/Recycling can Provide Significant Purification/Recycling can Provide Significant

Chemical, Water, Energy and Cost SavingsChemical, Water, Energy and Cost Savings

Mapping and Modeling to Support Process Improvement

Mapping and Modeling to Mapping and Modeling to Support Process ImprovementSupport Process Improvement

A - Process Step Sequence/General Arrangement

A A -- Process Step Sequence/General Process Step Sequence/General ArrangementArrangement

B - Process Level Diagram and Calculated Results Show Flow Balance, Energy, Material Use, and Costs

B B -- Process Level Diagram and Calculated Results Show Process Level Diagram and Calculated Results Show Flow Balance, Energy, Material Use, and CostsFlow Balance, Energy, Material Use, and Costs

B - Process Cost Report Itemizes Nine Cost Categories for Each Process

B B -- Process Cost Report Itemizes Nine Cost Process Cost Report Itemizes Nine Cost Categories for Each ProcessCategories for Each Process

B - Modeling Production Ranges Produces Ranges for Flows, Energy, Material Use, and

Annual Costs

B B -- Modeling Production Ranges Produces Modeling Production Ranges Produces Ranges for Flows, Energy, Material Use, and Ranges for Flows, Energy, Material Use, and

Annual CostsAnnual Costs

How Process Mapping & Modeling Supports Process Optimization

How Process Mapping & Modeling How Process Mapping & Modeling Supports Process OptimizationSupports Process Optimization

• Visualize process steps/production flow and interactions with other process, support, and facility systems

• Support identification, quantification and prioritization of opportunities for process improvement

• Improve “right-sizing” and allowances for future change for specific production range variation

• Provide quantifiable support and documentation for decisions

• Visualize process steps/production flow and interactions with other process, support, and facility systems

• Support identification, quantification and prioritization of opportunities for process improvement

• Improve “right-sizing” and allowances for future change for specific production range variation

• Provide quantifiable support and documentation for decisions

Information & Control Systems Improve Performance and Efficiency

Information & Control Systems Information & Control Systems Improve Performance and EfficiencyImprove Performance and Efficiency

A -Tests are Set-up to Take Inputs and Calculate Results by Consistently Using Equations and

Applying Rules

A A --Tests are SetTests are Set--up to Take Inputs and Calculate up to Take Inputs and Calculate Results by Consistently Using Equations and Results by Consistently Using Equations and

Applying RulesApplying Rules

A - Process Component-specific Trend Charts and Statistics are Automatically Generated

A A -- Process ComponentProcess Component--specific Trend Charts specific Trend Charts and Statistics are Automatically Generatedand Statistics are Automatically Generated

A - Rule Setups, with “E-Mail Message”, “Execute Script” and Other Actions

A A -- Rule Setups, with Rule Setups, with ““EE--Mail MessageMail Message””, , ““Execute ScriptExecute Script”” and Other Actionsand Other Actions

A - Rules & Logic Are Used to Automatically Initiate Actions to Improve

Process Control

A A -- Rules & Logic Are Used to Rules & Logic Are Used to Automatically Initiate Actions to Improve Automatically Initiate Actions to Improve

Process ControlProcess Control

B - Web-based Dashboards Broadcasting Visual Status Summaries can be Customized for QC Managers,

Engineers, Operators, Lab Technicians, etc

B B -- WebWeb--based Dashboards Broadcasting Visual Status based Dashboards Broadcasting Visual Status Summaries can be Customized for QC Managers, Summaries can be Customized for QC Managers,

Engineers, Operators, Lab Technicians, etcEngineers, Operators, Lab Technicians, etc

C – Process Documentation and Control Enhancement for Manual Lines

C C –– Process Documentation and Control Process Documentation and Control Enhancement for Manual LinesEnhancement for Manual Lines

Successful Process Transformation

Successful Process Successful Process TransformationTransformation

Why Transformation Fails (John P. Kotter – Harvard Business Review … based on more than 100 companies trying to remake themselves)

Why Transformation FailsWhy Transformation Fails (John P. Kotter (John P. Kotter –– Harvard Business Review Harvard Business Review …… based on based on more than 100 companies trying to remake themselves)more than 100 companies trying to remake themselves)

• Not enough urgency• Lack of vision• Undercommunicating the vision• Not removing obstacles• Not systematically planning/achieving short-term

wins • Declaring victory too soon• Not anchoring change in corporate culture

• Not enough urgency• Lack of vision• Undercommunicating the vision• Not removing obstacles• Not systematically planning/achieving short-term

wins• Declaring victory too soon• Not anchoring change in corporate culture

Systematic Transformation (E’s of Transformation)

Systematic Transformation (ESystematic Transformation (E’’s of s of Transformation)Transformation)