Client & Challenge:
A supplier of military vehicle parts was experiencing difficulty getting a consistent, high-quality zinc phosphate coating. After years of system and service representative changes, this customer was left with many unanswered questions.
Solution:
Accessa was called-in and performed an in-depth line audit that included equipment inspection, titrations, and bath analyses.
The results of this in-depth audit by Accessa had them lead a team approach with the customer, equipment partners, and nozzle suppliers. Utilizing Accessa’s experience and expertise, several projects were initiated.
The first project fixed an oil separator on the cleaner system that had been inoperable for several years. By fixing this separator, oil accumulation in the cleaner stage was significantly decreased, thus increasing the useful life of the said cleaning stage by several weeks.
The second project was addressing chemical usage. Several stages in this seven-stage washer were using excessive chemistry to try and fix perceived quality issues. In fact, the addition of this additional chemistry was only making the problems worse. Accessa suggested bringing the chemicals into appropriate ranges by adding an additive to the Bonderite ZM1 Zinc Phosphate stage to address the quality concerns. These changes resulted in lowering chemical cost by 7%, while also solving the quality concerns with the use of the additive.