12 Proven Tips to Save Time & Money for

Aluminum Anodizing, Hardcoat, and Other Metal

Finishing Services
 Tip 1: Upgrade Packaging
Invest in re-usable plastic shipping & packaging containers:
Re-usable
Shipping Containers
þ Less Waste
þ Better Quality
þ Increased Labor Efficiency
Part Sized Inserts Plastic Bins
Adopt: Re-usable plastic packaging. Normal pay back after 10 shipments vs. single
use containers and more quickly if parts are damaged.
Avoid: Paper, cardboard & bubble wrap and hand wrapping
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
Adopt: Reduce time to pack & unpack parts
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)
Tip 1: Upgrade Packaging
Advantages & Disadvantages

<<< Cardboard / Single Use Plastic/Multiple

Use>>>
Advantages Advantages
• Initially inexpensive • After initial payback, more cost effective
• Lightweight • Longevity
• Ideal for non-returnable applications, i.e., • Constant Tare
exports • Purchase or Rental as required
• Recyclable • Secure stacking in storage and transit
• Nests/folds for storage
Disadvantages • Better protection of contents
• Cost of collection and disposal • Operator comfort and safety
• Have to purchase in bulk • Traceability
• Storage • Weatherproof
• Limited protection • Non-absorption of contaminants
• Time consuming to assemble • Cleanable
• Staples, splinters can damage contents • Recyclable/sustainability compliance
• Not weatherproof
Disadvantages
• Initially expensive
• Weight
• Cost, if not returned

Resources: http://www.amatechinc.com/services/calculator
 Tip 2: Systemize the Paperwork
4 Steps to faster turnaround and better quality

1 2
Email / Fax copy of Include original
Purchase paperwork with the
Order order. Place all
documents in clear
plastic pouch on top
of parts in sealed box.
3 4
Include all paperwork For each part, include:
with order: • Surface Area
• Purchase Order • Alloy
• Part # or Unique ID
• Shipping
Docs • Clear Masking
• Print for each part instructions
• Exact Finishing
Instructions
• Where / where not to
rack
• Color sample (if color
match required)

þ Better Quality Eliminate rework and/or scrap due to

• Jobs improperly run
þ Increased Labor Efficiency Engineering and contract review can start immediately.

þ Faster Turn Times Jobs get to production – and back to the customer - more quickly.
Tip 2: Systemize the Paperwork
In summary

Email / Fax Copy of • Start order entry while materials are in transit.
Paperwork • ID issues earlier to resolve w/o delay
Original Paperwork • Identification and traceability during receiving
with Order • Plastic pouch protects documents
Include all • Faster Contract & Engineering Review
paperwork

The goal is to get the parts into production as quickly as possible without
risking poor quality.
Tip 2: Systemize the Paperwork
Product instructions

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 • Faster Contract review. Show masking locations on print.

Instructions
Clear Processing • Best success is achieved by detailed and non-conflicting finishing instructions.
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.
 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 Different smelters may have the same specification but produce slightly different
Alloys products. All of the same impacts as above, but to a lesser degree.

þ Better Quality The same alloy and same supplier will reduce process variations leading to poor
quality.
þ Faster Turn Times No need to put jobs on hold and work through a disposition and/or rework.
 Tip 4: Work Out a Schedule

• Achieve a balanced work flow with your supplier

• Constant speed beats fast / slow every time.

þ Increased Labor Efficiency Labor, materials, and process time can be scheduled to avoid unnecessary queue time.

þ Faster Turn Times Jobs get to production – and back to the customer - more quickly. Reduces risk of
disorganization and mistakes.
 Tip 5: Establish a Standard Order Size

Single order size 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

þ Better Quality Standard orders can be optimized. Racking can be optimized. Process conditions can
be standardized.
þ Faster Turn Times No requirement for engineering and contract review if the order stays the same. Can
get to production more quickly.
 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

þ Less Waste Titanium racks do not wear out and do not need to be replaced.

þ Better Quality Eliminate rework and/or scrap by better drainage and rinsing

þ Increased Labor Efficiency Adopt: Reduce time to pack & unpack parts
 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

Metal Shavings & Burrs Left over from machining, etc. Burn marks / bare spots

Other metals Cross contamination from bead blasting Burn marks

media
Wet Parts Water / Moisture Poor packaging, storage, and/or Corrosion & staining
transportation

þ Better Quality Eliminates need for disposition during receiving.

Parts can follow job standard process without special steps.
Eliminates major cause of poor quality.
þ Reduced Lead Time Eliminate extra processing steps and incidence of rework.
Tip 7: Eliminate Contamination
Illustrations

Oils & Shavings Adhesives left from Moisture

protective wrap
 Tip 8: Reduce # of Approved Suppliers

Choose a supplier who has the best fit with your organization’s needs based on:
• Anodizing expertise and ability to solve problems. Often one needs to get beyond how the
part looks to understand what can be accomplished.
• Understanding of your business needs.
• The quality / timeliness of the suppliers communication with you.
• Your company size & the sense of priority you think you may have.
• Service level (i.e., turn times, pick up / drop off services, etc.).
• Overall defect rate (rework and SCARS) and ability to work with you to reduce defects
and lower rework and scrap costs.
• The completeness of their product offering to meet your overall manufacturing needs.
• Risk profile in respect to organization depth, upkeep of facilities and equipment, and systems.
• Value added and proprietary services that help you upsell your
products or reduce overall costs.
• Certified QMS through a respected accrediting organization.

þ Better Quality Eliminates variance between suppliers.

Improves communication by eliminating duplication of instructions and special needs.
….

þ Increased Labor Efficiency ….

 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.

þ Reduce Cost Avoid: Use of Fed Ex Overnight and UPS Red services.
 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.

þ Increased Labor Efficiency Adopt: Streamlined communication

 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.

þ Reduce Cost Depending on payment terms, early payment discounts can reduce prices by 1 – 3%

þ Increased Labor Efficiency No need to make payment calls.

 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

þ Less Waste Reduce unnecessary transport & handling and associated lead times.

þ Better Quality Clearer accountability.

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.
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.
1 Shorr Court
Woonsocket, RI 02895
United States of America
Tel: (401) 597-5000
www.sanfordprocess.com