ahmadkhan_99@hotmail.com1

• Introduction

Process Design- OEM Perspective

Process Operation – Operator Perspective

Process Qualification Concerns

Product Quality Concerns

How to Improve Process Quality

Focus Point – Process Criticalities

2

• Seminar Overview

Surface Treatment – An Overview

Pre-Processes & Criticalities

Plating Processes & Criticalities

Post Processes & Criticalities

Review of Some Existing Plating Processes

3

Processes Design- OEM Perspective

A process is designed after extensive studies,

research work verified by experiments

Thus; each and every step as described by the

OEM has its own importance and implications;

may it be a simple / repetitive step e.g too

many hot-wash, cold-wash, blowing dry air or

ensuring continuity of some steps in the

process

4

Processes Operation – Operator Perspective

Process operators take the process as a set of certain

steps to be performed with a sole concern of

acceptance / rejection of out-coming products

Operators, over a period of time, based on their

observations / experience start taking shortcuts /

omitting process steps, which they think, do not have

any effect on the product &

Their assumptions remain true due to various reasons

like non-detection of underlying adverse effects,

incapacitation of process control parameters being

monitored to show the effects 5

Process Qualification Concerns

Specifications/requirements of process qualification

as specified by the OEM be met/ensured/monitored

Product Quality Concerns

Is the product coming out of a process a Quality

Product?

Who/How a product will be defined as Quality

Product. Answer is “ in our case Products meeting

OEM’s requirements & in general Products meeting User’s requirements” 6

How to Improve Process/Product Quality

Process Qualification Implementation

Intelligent Embedding of Quality Control Element

Knowing What, Why & How of the Process

Process Criticalities' Awareness

7

Focus Point – Process Criticalities

Process Criticalities can only be understood / ensured

through

Knowing What, Why & How of the Process

8

Surface Treatment An Overview

Finishing and Polishing

Coatings

Deposition

Organic Coatings

9

Pre-Processes Surface Preparation

Mechanical Preparation Blast Finishing

Shot Peening

Mass Finishing

Polishing

Buffing

Chemical Preparation

Pre-process Baking

Preheating

Effects of Discontinuity in process

Effects of Poor Cleaning process10

Plating Process & Criticalities

What & Why of Elctroplating

Factors Influencing Electro Deposition

Current density

Cathode Efficiency

Agitation

Bath composition & Solution concentration

Water Requirement

The presence of impurities & Filtration

Hydrogen Embrittlement and its Effects

11

Post Processes & Criticalities

Drying with Air (Hot/Cold)

Post Process Baking

Hot / Cold Water Rinse

Heat Treatment

Inspection

Quality Control

12

Review of Some Existing Plating Processes

Lead – Indium

Zinc Plating

13