A service provider of aluminum anodizing, DCHN guide to cost-effective ways for Aluminum Anodizing, Hardcoat, and Other Metal Finishing Services.

1. 12 Proven Tips to Save Your Time & Money for
Aluminum Anodizing, Hardcoat, and Other Metal
Finishing Services
2014 Guide
© 2014 Katahdin Industries Inc.

2. Tip 1: Upgrade Packaging
Invest in re-usable plastic shipping & packaging containers:
Re-usable
Shipping Containers
Part Sized Inserts
Plastic Bins

Less Waste
Adopt: Re-usable plastic packaging. Normal pays back after 10 shipment vs. single
use containers and more quickly if parts are damaged.
Avoid: Paper, cardboard & bubble wrap and hand wrapping

Better Quality
Eliminate rework and/or scrap due to
• Part on Part contact
• Metal ties on part contact
• Damage due to excessive part movement and/or incomplete part protection
• Contamination & moisture

Increased Labor Efficiency
Adopt: Reduce time to pack & unpack parts

3. Tip 1: Upgrade Packaging
Savings Factors
Direct Cost Savings
• Packaging materials: usage/wastage/storage
• Damage to parts in transit: scrap & rework cost
• Labor costs: Time to wrap/unwrap
• Transportation cost: Less than optimal pack density
Indirect Savings
• Lower inventory (eliminate safety / make up stock)

4. Tip 1: Upgrade Packaging
Advantages & Disadvantages
<<< Cardboard / Single Use
Use>>>
Advantages
• Initially inexpensive
• Lightweight
• Ideal for non-returnable
applications, i.e., exports
• Recyclable
Disadvantages
• Cost of collection and disposal
• Have to purchase in bulk
• Storage
• Limited protection
• Time consuming to assemble
• Staples, splinters can damage contents
• Not weatherproof
Plastic/Multiple
Advantages
• After initial payback, more cost effective
• Longevity
• Constant Tare
• Purchase or Rental as required
• Secure stacking in storage and transit
• Nests/folds for storage
• Better protection of contents
• Operator comfort and safety
• Traceability
• Weatherproof
• Non-absorbtion of contaminants
• Cleanable
• Recyclable
Disadvantages
• Initially expensive
• Weight
• Cost, if not returned
Resources: http://www.amatechinc.com/services/calculator

5. Tip 2: Straighten out the Paperwork
4 Steps to faster turnaround and better quality
1
Email / Fax copy of
Purchase
Order
2
3
4
Include original
paperwork with the
order. Place all
documents in clear
plastic pouch on top
of parts in sealed box.
Include all paperwork
with order:
For each part, include:
•
•
•
Purchase Order
Shipping
Docs
Print for each part
•
•
•
•
•
•
•
Surface Area
Alloy
Part # or Unique ID
Clear Masking
instructions
Exact Finishing
Instructions
Where / where not to
rack
Color sample (if color
match required)

Better Quality
Eliminate rework and/or scrap due to
• Jobs improperly run

Increased Labor Efficiency
Engineering and contract review can start immediately.

Faster Turn Times
Jobs get to production – and back to the customer - more quickly.

6. Tip 2: Straighten out the Paperwork
Email / Fax Copy of
Paperwork
• Start order entry while materials are in transit.
• ID issues earlier to resolve w/o delay
Original Paperwork
with Order
• Identification and traceability during receiving
• Plastic pouch protects documents
Include all
paperwork
• Faster Contract & Engineering Review
The goal is to get the parts into production as quickly as possible without
risking poor quality.

7. Tip 2: Straighten out the Paperwork
Information
Explanation
Alloy
•
Different alloys process differently and will impact coating build rate, oxide
color, hardness, dielectric properties, and risk of burning.
Surface area of part
•
For accurate and consistent coating thickness. Processing requires calculation
of total surface area to run the job – starts with the total surface area of one
part. If you have a print, you most likely can quickly calculate surface area.
Incoming Dimensions
•
For hardcoat, communicate dimensions for critical areas to allow calculation of
metal removal for cleaning and cosmetics before coating build. Show on print.
Unique Part Number
•
Traceability and accurate recall of process steps and price.
Racking Location
•
Avoid guesses of where / where not to rack. Show on print.
Clear Masking
Instructions
•
Faster Contract review. Show masking locations on print.
Clear Processing
Instructions
•
Best success is achieved by detailed and non-conflicting finishing instructions.
Be clear on expectations such as gloss or matt finish.
Color
•
Provide high and low color samples when color match is important. PMS
charts, paper color, paint chips or similar are poor options unless nothing else
exists.
Complete information allows for faster contract and engineering reviews and eliminates many causes of poor
quality.

8. Tip 3: Control the Aluminum Alloy
Issue
Explanation
Never Mix Alloys
Different alloys process differently given the various constituent alloying metals in
aluminum.
• Different coating build rate.
• Different conductivity of metal
• Different inclusions of alloying elements in coating
Mixing allows can lead to:
• Color and surface appearance variations
• Different quality of oxide: hardness, corrosion resistance, dielectric, and
propensity to crazing.
• Burning of parts due to different conductivity levels of alloys
• High coating thickness variations
Single Source Same
Alloys
Different smelters may have the same specification but produce slightly different
products. All of the same impacts as above, but to a lesser degree.

Better Quality
The same alloy and same supplier will reduce process variations leading to poor
quality.

Faster Turn Times
No need to put jobs on hold and work through a disposition and/or rework.

9. Tip 4: Work Out a Schedule
• Achieve a balanced work flow with your supplier
• Constant speed beats fast / slow every time.

Increased Labor Efficiency
Labor, materials, and process time can be scheduled to avoid unnecessary queue time.

Faster Turn Times
Jobs get to production – and back to the customer - more quickly. Reduces risk of
disorganization and mistakes.

10. Tip 5: Establish a Standard Order Size
Single order sized optimized around anodic coating process
• Normally surface area is limited by size/capacity of the process tank.
• Overall dimensions of parts may be critical
• Other tanks may impose limitation as well (pre-process, dye, etc.).
Work with your metal finisher to agree optimal load sizes and package accordingly.
Reduce set up times by having a complete process standard &
avoid changing run conditions

Better Quality
Standard orders can be optimized. Racking can be optimized. Process conditions can
be standardized.

Faster Turn Times
No requirement for engineering and contract review if the order stays the same. Can
get to production more quickly.

11. Tip 6: Invest in Custom Titanium Tooling
Titanium Racking:
• Racks last many years and hundreds of runs
• No need to strip between uses
• Design rack to:
• Optimize load sizes
• Prevent damage to parts
• Allow for optimal draining / rinsing
• Master frame and spline racks can be used
with racking machines for higher productivity
*See blog post….+

Less Waste
Titanium racks do not wear out and do not need to be replaced.

Better Quality
Eliminate rework and/or scrap by better drainage and rinsing

Increased Labor Efficiency
Adopt: Reduce time to pack & unpack parts

12. Tip 7: Eliminate Contamination
Factor
Risk Item
Possible Sources
Impact
Contaminants
Adhesives
Protective films, bonding agents, etc.
Missing coating
Excessive Oils
Machining and tooling oils
Shavings & Burrs
Left over from machining, etc.
Burn marks / bare spots
Other metals
Cross contamination from bead blasting
media
Burn marks
Water / Moisture
Poor packaging, storage, and/or
transportation
Corrosion & staining
Metal
Wet Parts

Better Quality
Eliminates need for disposition during receiving.
Parts can follow job standard process without special steps.
Eliminates major cause of poor quality.

Reduced Lead Time
Eliminate extra processing steps and incidence of rework.

13. Tip 3: Eliminate Contamination
Oils & Shavings
Adhesives left from
protective wrap
Moisture

14. Tip 8: Reduce # of Approved Suppliers
Choose a supplier(s) who has/have the best fit with your organization’s needs based on:
•
•
•
•
•
•
•
•
•
•
Their anodizing expertise and ability to solve problems. Often one needs to get beyond how the
part looks to understand what can be accomplished.
Their understanding of your business needs.
The quality / timeliness of the suppliers communication with you.
Your size & the sense of priority you think you can / do have.
Their service level (i.e., turn times, pick up / drop off services, etc.).
Their overall defect rate (rework and SCARS) and their work with you to reduce defects
and lower rework and scrap costs.
The completeness of their product offering to meet your overall manufacturing needs.
Their risk profile in respect to organization depth, upkeep of facilities and equipment, and systems.
Whether they have value added and proprietary services that help you upsell your
products or reduce overall costs.
Whether they have a certified QMS through a respected accrediting organization.

Better Quality
Eliminates variance between suppliers.
Improves communication by eliminating duplication of instructions and special needs.
….

Increased Labor Efficiency
….

15. Tip 9: Reduce Usage of Expedited Services
Too often, the expected price for running the job is lost when premium
services are employed to meet schedule – either by rushing jobs or by
using more expensive shipping options such as overnight delivery.
These services can be reduced and often eliminated.
Start by reviewing your shipping costs to see how much you are spending on
premium services. If after following all the recommendations you still require
the use of such services, try to arrange for a volume discount.

Reduce Cost
Avoid: Use of Fed Ex Overnight and UPS Red services.

16. Tip 10: Establish Contact Sheets
Be clear on whom the supplier should contact for:
- Contract Review issues
- Quality concerns
- Shipping
- Payment
Provide Name, Title, Phone, and email!
…and then ask the supplier for the same.

Increased Labor Efficiency
Adopt: Streamlined communication

17. Tip 11: Negotiate Payment Terms
Negotiate early payment discounts.
Your metal finishers main cost is labor that is paid weekly with the other costs
typically net 30. Therefore, most companies will agree to an early payment discounts
such as 2%/10 Days.

Reduce Cost
Depending on payment terms, early payment discounts can reduce prices by 1 – 3%

Increased Labor Efficiency
No need to make payment calls.

18. Tip 12: Combine Value Added Services
Choose a finisher who can provide additional services to eliminate unnecessary
handling while reducing costs and complexity.
• Proprietary metal finishing technologies that solve design and engineering
challenges
• Printing & laser engraving
• Light assembly

Less Waste
Reduce unnecessary transport & handling and associated lead times.

Better Quality
Clearer accountability.

19. Summary
•
•
•
Changes can result in significant cost savings and reductions
in turn time.
Improvements are sustainable, proven, and win-win.
Deepens the relationship and trust with your supplier.

20. Continuous Improvement Action Plan
•
•
•
Work with your supplier on a balanced score card for key
operating metrics such as OTD, Turn Times, Defects in
Process / Rework, Paperwork Errors, DSO and SCARs,. Use
prior six months as baseline to track improvements and
impact of initiatives.
Identify and work on one or two initiatives maximum at a
time.
Complete the initiative, assess the impact, identify areas of
further improvement before starting the next one.