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# OAR Box 

# 1313 Preppedby LaTeiaShed



### Document

Number: 

# 62 ) ll-B-3 6
Docket Number: 

# A-88-0 2

Printed 6/12/20089:03:30AM

Sheet 62 of 99P. 2

V 

# MRI® A-88-02 MIDWESTRESEARC H INSTITUT ' IT-"£-3(4 , Suit e 3f : 40 1 Hamso n Oaks Bouteva t

Cnrv

. NC

. 275 !

Date : Ma

y 17 , 198 8 Subject : Technica l Revie w o f th e ProductionRat e Analyse s b y JAC A Corporation Chromiu m Electroplating NESHA P EP A Contrac t 68-02-3817 ; ES D Projec t 85/02 a _ . „-—~ - MR I Projec t 7717- K[^"ZT RM T i? , \ r 

# yx ^:s.Lx.ssx.~- -* \ From : Robi nBarker^ " Z.. 7 !. ; , ; M ; -t

- •••' .sy \y..y To : Andre

w Smit h ESD/ISB/SS S (MD-13 ) U . S . Environmenta l ProtectionAgency ResearchTriangl e Park , N.C . 2771 1 I . Purpos e Th e purpos e o f thi s memorandu m i s t o presen t the technica l issue s concerning individua l proces s parameter s use di nthe derivatio no f har d an ddecorative chromiu m plating mode l plan t productio nrate s fo r specified en dproducts . Som

e o f thes e issue s wer e discusse dwit hMr . Wayn e Morr a o f JAC A Corporation(JACA ) ina telephon e conversationwit hRobi nBarke r o f Midwes t ResearchInstitut e (MRI ) o nMa y 4 , 1988 . Th e end-produc t parameter s developedb y JAC A ar e use

dt o determin e the economi c impact s presentedi

nBI D Chapte r 8 . Thes e end-produc t parameter s ar e presentedi n Attachmen t 1 . Th

e specifi c parameter s i nquestionar e (1 ) plat e thickness , (2 ) uni t surfac e are a o f parts , an d (3 ) the productio nrat e assumptions . II . Plat e Thicknes s Th e plat e thicknesse s develope db y JAC A an d presente di

nBI D Chapte r 8 for faucets , sockets , ratchets , an d automobil e part s appea r to b e incorrec t base

do navailabl e information . The plat e thicknes s given fo r thes e decorative chromiu m platedproduct s ar e equa l t o o r greate r tha n 1 thousandt ho f a

ninc h(mil) . The maximu m plat e thicknes s fo r decorative chromiu m application s i s 1 mil . Mos t decorativ e chromiu

m electroplater s include di nth e Section11 4 dat a bas e an d tri prepor t dat a bas e plat e part s withthicknesse s ranging fro m 0.0 1 t o 0. 2 mils . Mr . Morr a respondedtha t a compute r progra m (Attachmen t 2 ) wa s use d t o calculat e th

e plat e thicknes s o r platin g tim e depending o

nwhic h variabl e wa s unknow

nfo r th

e give nen

d product . Also , Mr . Morr a state d tha t th e plat e thicknes s specifiedi nmil s wa s incorrec t becaus e a mi l wa s interpreteda s a milliont ho f a ninc hinstea do f a thousandt ho f a n inch . Whe

nth e correc t conversio nfactor i s applie dt o conver t inche s t o mils , th

e plat e thicknesse s appea r representativ e o f plat e thicknesse s

/P. 3

applie di ndecorativ e chromiu m plating . T o ensur e tha t th e mean s o f calculatin g plat e thicknes s i s consisten t betwee nth e BI D chapters , MR I i s providin g th e followin g equatio nfo r calculatin g plat e thicknes s o r platin g time : Z = XY/51 8 (plat e thickness )
o r Y= Z 518/ X(platin g time ) where , X= curren t densit y i namperes/squar e foo t (A/f t ) Y= platin g time i nhour s (h ) Z = plat e thicknes s i nmil s 51 8 = electrochemica l equivalen t a t 1 0 percen t cathod e efficienc y in A-h/rall-f t III . Uni t Surfac e Are a o f Par t Th e uni t surfac e are a develope db y JACA an dpresente di nBI D Chapte r 8 fo r industria l roll s andhydrauli c cylinder s appear s inconsisten t wit hinformatio nobtaine dthroug hth e Sectio n11 4 informatio n request s an

dth e tes t program . Dat a obtaine ddurin g a nemissio ntes t a t Rol l Technology , Inc. , indicat e tha t anaverag e surfac e a^e a o f an industria ] rol l i s approximatel y 1,00 0 squar e inche s (in . ) instea do f th e 4,00 0 in . tha t JAC

A currentl y

i s using . Dat a obtaine dthroug h Sectio n11 4 informatio nrequest s fro m har dchromiu

m platin g plant s indicat e tha t typica l syrfac e are a value s fo r a hydrauli c cylinde r rang e fro m 1,00 0 t o 1,50 0 ic* . . Th e valu e give nb y JACA fo r a hydrauli c cylinde r i s 271. 4 in . . Therefore , MR I recommend s tha t th e uni t surfac e are a value s give nfo r thes e endproduct s b e revise da s follows : 2 Uni t surfac e are a o f anindustria l rol l = 1,00 0 in . Uni t surfac e are a o f a hydrauli c cylinde r = 1,25 0 in . IV . Productio nRate s Assumption s Th e productio nrat e assumption s develope db y JAC A an dpresente di n BI D Chapte r 8 fo r eac hend-produc t ar e base do ndat a obtaine dfrom plants . Thes e dat a shoul dno t b e use dt o characteriz e productio nrate s o f th e mode l plant s because : (1 ) th e productio nrat e fo r a give nplan t i s directl y proportiona l t o th e tota l workin g volume o f th e plan t an dwoul d needt o b e adjuste dt o matc hth e workin g volume s o f the mode l plant s an d (2 ) i t appear s tha t som e productio nassumption s obtaine dfro m plant s wa s incorrectl y

interpreted . Fo r example , on e o f th e productio nrat e assumption s fo r ratchet s wa s tha t a rac k hold s 5 0 squar e fee t o f surfac e area . On e rac k o f part s coul dno t hol d5 0 squar e fee t o f surfac e area ; however , th e tan

k capacit y

i nterm s o f par t surfac e are a ma y be 5 0 squar e feet .

at-P. 4

I nth e conversatio nwit hMr . Morra , thes e concern s wer e presente d an dMr . Morr a state dtha t th e productio nrat e assumption s woul db e revise d base do ndat a derive db y MR I onth e productio ncapacit y fo r th e individua l mode l plants . Thes e dat a ar e presente di nTable s 1 an d2 fo r eac hhar d an ddecorativ e chromiu m electroplatin g mode l plant , respectively . An exampl e calculatio nfo r derivin g th e productio nrat e insquar e footag e pe r yea r an dpart s pe r yea r i s presente di nAttachmen t 3 fo r bot ha har dan d decorativ e chromiu

m platin g mode l plant . Also , presente di nAttachmen t 3 ar e example s o f ho

w th e informatio npresente dinTable s 1 an d2 shoul db e use dt o characteriz e th e mode l plan t productio nrat e interm s o f rac k population s o r tota l tan k capacities . Th e productio nrate s fo r th e mode l plant s ar e input s t o a compute r program whic hcalculate s platin g costs . Thi s progra m wa s develope db

y modifyin g th e progra m presente di nAttachmen t 4 . Modification s wer e necessar y

sinc e th e progra

m inAttachmen t 4 wa s writte nfo r barre l platin g operations , a typ e o f operatio nno t use dinth e mode l plants . Prope r documentatio nfo r thes e modification s wil l b e neede dfo r futur e review s o f draft s fo r BI D Chapte r 8 . Thi s documentatio nwoul denabl e reviewer s t o bette r asses s whethe r thi s program i s appropriat e fo r calculatin g platin g cost s fo r specifi c operations . 4 Attachment sP. 5

TABL E 1 . PRODUCTIO N

RAT E ASSUMPTION S FOR HARD CHROMIU

M PLATINGOPERATION S Productio ncapacity , Plan t size/tan k siz e squar e fee t o f parts a
Smal l mode l plan t Mode l tan k . 1 < ? (12.0,3.5,6.0) D2 8 Tota l 2 8 Mediu m mode l plan t Mode l tank s 

### 1 8 1 @ (4.0,4.0,10.0) J 2 @ (12.0,4.0,6.0) ° 2 @ 3 2 1 @ (25.0,3.0,6.0) D 

### _5 0 Tota l 13 2 Larg e mode l plan t Mode l tank s . 2 @ (4.0,4.0,10.0) ? 2 e 1 8 4 < ? (12.0,4.0,6.0) ° 4 < P 3 2 • 2 § (25.0,3.0,6.0) D2 @_5 0 Tota l 26 4

a Surfac e are a o f part-to-volume o f tank rati o i s 0.1 2 f t /f t . Productio n facto r i s base do nmaximu m valu e fro

m tes t dat a a t har dchromiu m platin g .facilities . Numbe r o f tank s i nmode l plan t an d th e length , width , an d dept ho f eac h tan k i nfeet . Tan k freeboar dspac e = 6 inches .



# fP. 6

TABL E 2 . PRODUCTIO N RATE ASSUMPTION S FOR DECORATIV E CHROMIU M PLATIN G OPERATION S

** " ' " ' "* " ' ' -^——-^
- _^_^_

_,. , . , . . _• . , , .. . 'TM!—!— • - ———— — 

### Plan t siz e Productio nrat e assumption s Small a 

### On e rac ko f part s every 2 f t o f tanklengt h(i.e. , si xrack s per tank ) Medium a 

### On e rac ko f part s every 2 f t o f tanklengt h(i.e. , si xrack s pe r tank ) Larg e On e rac ko f part s ever y 6 f t o f tanklengt h(i.e. , tw o rack s pe r tank )

a 

### Base do ndat a obtaine dfro m sourc e tes t a t Automati c Di e Castin g .Specialists , Inc . D 

### Base do ndat a obtaine dfro m sourc e tes t a t Delc o Product s Division , Genera l Moto r Corportion . Economi c impact s fo r th e larg e mode l plan t shoul db e base do nbumpe r productio nonly .



### \SP. 7



### Attachmen t 1 . End-Produc t Parameter s Develope db y JACA Corporatio nP. 8

FAUCET S Firm s Contacted : Delt a Faucets , Masc o Corp . America nStandar dInc . Stanadyne , Inc . Sterlin g Fauce t Compan y Parametri c Value s o f Selecte dFauce t Surfac e Are a Curren t Densit y Platin g Thicknes s Platin g Time Productio nAssumption s Rac k Hold s Productio nRat e Labo r Cos t Overhea dFacto r Profi t Facto r Commissio nFacto r 88. 5 sq . inc . 60-7 5 amps/sq . f t 10-2 0 mil s 4 mins .

5 0 sq . ft . 1 2 rack s pe r hou r $1 2 pe r hou r 2. 5 10 % 15 % Uni t Cos

t $.3 8



# 7P. 9

HAN D TOOL S Firm s Contacted : S KHan dTool s Cor p Stanle y Work s Inc . Snap-O nTool s Cor p Easc o Corp . L.S . Starret t Inc . •

•
Vermon t America nCorp . Peterse nManufacturin g Co. , Inc . (Nickel ) Parametri c Value s o f Selecte dHandTool s

Surfac e Are a Curren t Densit y Platin g Thicknes s Platin g Time Productio nAssumption s

Rac k Hold s Productio nRat e Labo r Cos t Overhea dFacto r Profi t Facto r Commissio nFacto r Uni t Cos t Socke t

3 sq . in . 5 0 amp s pe r sq . ft . 1 mi l 4 mins .

Socke t 5 0 sq . f t 1 2 racks/hr . $12/hr . 

### 2. 5 10% 15 % $.01 3 Rache t

2 5 sq . 1n . 6 0 amp s pe r sq . ft . 1 mi l 4 mins .

Rache t 5 0 sq . ft . 1 2 racks/hr . $12/hr . 

### 2. 5 10% 15 % $.1 1 Tap e Measur e

1 4 sq . 1n . 40 0 amp s pe r sq . ft . .01 5 mil s 1 5 mins .

Tap e Measur e 5 0 sq . ft . 3 racks/hr . $12/hr . 

### 2. 5 10% 15 % $.2 4

/AUTOMOBIL E PART S

Firs t Contacted : P.1 0

Dur a Platin g Genera l Motor s Corp . America nMotor s Corp . Allie dFinishin g Moto r Vehicle s Manufacturer s Assoc . Automotiv e Informatio nCounci l Societ y o f Automotiv e Engineer s Moto r andEquipmen t Manufact urer s Associatio n Chrysle r Corp . FordMoto r Corp . Thompso nIndustrie s Bumpe r Recyclin g Associatio no f Nort hAmeric a Nationa l Assocatio no f Aut o Tri m Shop s Moto r Vehicl e Manufacturer s Association , Inc . Parametri c Value s o f Selecte dAutomobile s

Surfac e Are a Curren t Densit y Platin g Thicknes s Platin g Tim

e ctio nAssumption s

Rac k Hold s Productio nRat e Labo r Cos t Overhea dFacto r Profi t Facto r Commissio nFacto r Electroplatin g Cos t Decorativ e 4 0 fee t 7 5 amp s sq . ft . 10-2 0 mil s 4 mins . Decorativ e 5 0 sq . ft . 1 2 rack s pe r hr . $12/hr . 2. 5 10 % 15 % $2 5 Har d 8 fee t 28 8 amp s sq . f t .00 1 inche s 2 . noun s
Har d 6 0 sq . ft . 1/ 2 rac k pe r hr $12/h4 . 2. 5 10 % 15 % $100.1 2P.1 1

INDUSTRIAL ROLL S Firm s Contacted : Chromiu m Industries , Inc . Ne w Castl e Industrie s Rol l Technolog y

Corp . Schmumacke r Corp . Souther nPlatin g Inc . Electrocoatln g Inc . Simmon s Platin g andMeta l Finishin g Co . Parametri c Value s o f Selecte dRol l Surfac e Are a 4,00 0 sq . 1n . Curren t Densit y

2 amp s pe r sq . in . Platin g Thicknes s .00 1 inche s Platin g Time 2 hour s Productio nAssumption s Tan k Hold s On e rol l Productio nRat e 1/ 2 rol l pe r hou r Labo r Cos t $1 2 pe r hou r Overhea dFacto r 2. 5 Profi t Facto r 10 % Commissio nFacto r 15 % Cos t pe r sq . in . $.1 0



### /< ?P.1 2



### BACKHOE S - HYDRAULI C CYLINDER S Firm s Contacted : JohnDeer e Co . Case , I . I . McKa y Platin g Co . Industria l Chrome , Inc . NAVISTA R(formerl y

Internationa l Havester ) Parametri c Value s o f Selecte dBackhoe-Hydraull c Cylinder s Surfac e Are a Curren t Densit y Platin g Thicknes s Platin g Time Productio nAssumption s Tan k Hold s Productio nRat e Labo r Cos t Overhea dFacto r Profi t Facto r Commissio nFacto r Cos t pe r sq . in . Cos t pe r backho e 271. 4 sq . 1n . 2 amp s sq . 1n . .00 1 Inche s 2 hour s

8 0 sq . ft . 4 0 sq . ft . pe r hr . $1 2 2. 5 10 % 15 % $.06 5 $17. 7

/ /P.1 3



### Attachmen t 2 . Compute r Progra

m Use db y JAC A Corporatio nt o Calculat e Plat e Thicknes s

/ >P. M



### 1 0 RE M STORE D A

T FARADA

Y - APROGRA

M T O CALCULAT E PLATIN G TIM E O

R THICKNES S 20 * RE M 'BA33 D O

M TABLE S FRO H VARIOU S GUIDEBOOK S 5 0 RE M PROGRAMME D B Y L.J.DURNE Y NOVEMBE R 193 3 4 0 CL 3 5 0 PRIM T T;u3(31);"Thi s i s FARADAY " 5 5 PRIN T TA:-3(i6);" a programt o calculat e Dlating thicknes s o r time " S O PRIMT:PRIN

T TAB(39);"by " 7 0 PRI'II : PRIN

T TA3 ( 3 1 ) ; "Lawrenc e J . Durney " 5 0 PRIMT TA3(32);"Novembe r 20,1983 " ? 0 FO R 1= 1 T O 2000:NEX T I 10 0 CL S 11 0 PRINT:PRINT:PRINT 12 0 PRIMT TAB(22);"Th e followin g option s ar e available: " 13 0 PRIMT:PRIN

T TAB(10);"1
. Calculat e plating time - are a known " 14 0 PRIMT 7AB(10);"2
. Calculat e platin g tim e - area unknow

n - barre l work " 13 0 PRIMT TABOO) ; "3
. Calculat e thicknes s - time - curren t - are a known " 1-3 0 PRIMT TAB(10);"4
. Calculat e weigh t o f coating - tim e - curren t - are a kno w 17 0 PRIMT:?RIN

T TAB ( 17);"Ente r the numbe r o f th e desire d program " 13 0 INPU

T 1 19 0 I F Z< 1 O

R Z> 4 THE NPRINT "Yo u hav e entere d a n invali d number
. Tryagain." : TO 17 0 20 0 O M Z GOT O 300,800,1900,190 0 30 0 RE M - PLATIN

G TIM E - ARE AKNOW N 31 0 CL S 32 0 PRINT:PRINT:PRINT 33 0 PRIMT TAB(23);"PLATIN G TIM E CALCULATION " 34 0 PRIMT-.PRIN

T TAB(10) ; "I t wil l estimat e th e prope r platin g time fo r any " 55 0 PRIMT TA3(10);"thicknes s needed. " 56 0 PRINT:PRIN

T TAB(10);"Yo u mus t kno w th e require d thickness, " 37 0 PRIN

T TA3(27);"th e are a o f a par t o r rac k loa d and " 53 0 PRIN

T TA3(27);"th e averag e curren t densit yneede d fo r goo d plating. " 5? 0 FO R 1= 1 T O 5000:NEX T I 10 0 CL S •11 0 PRINT : PRINT : PRIMT

- •£ 0 PRIN

T TA3(10 ) ; "V/ha

t meta l i s t o b

e plated? " 4 5 0 PRIMT TA3(10);"Ente r ful l nam e in capita l letters. " 44 0 INPU

T 3 3 •150 G0SU 3 320 0 'GE T DAT A 46 0 PRINT:PRINT—"Ente r th e require d thicknes s -i-n-inches e.g . .00 1 o r .0002. " 47 0 INPU

T T ...;." . 43 0 PRINT:PRIN

T "Ente r th e surfac e are a o f the par t o r rac k i n squar e feet. " 49 0 PRIN

T "Do no t us e fractions
. I f necessaryus e decimals " 50 0 INPU

T 3 51 0 PRINT: D 

### RINT"Ente r the averag e curren t densit yt o b e used. " 52 0 PRIMT "Ente r a s amp s pe r squar e foot. " 550INPU

T ? 54 0 R=3* P 55 0 M=(T*1000)*D*50/ P 55 0 CL S 57 0 PRIMT:PRIN

T TAB(10);"A t 1005 5 efficiency , i t wil l requir e ";M; " minutes " 53 0 PRIMT T-\3(15);"t o deposi t a thicknes s o f ";T; " inches. " 59 0 FRIMTtPRIMT TABOO) ; "I t wil l requir e ";R; " ampere s pe r part/rack. " 60 0 PRINT:PRIMT TAB(10);"Yo u wil l have t o adjus t thi s tim e if "



## /SP.1 5



### 61 0 62 0 a s 630 ' 54 0 55 0 oo O 57 0 53 0 59 0 70 0 71 0 72 0 73 0 30 0 31 0 32 0 33 0 84 0 85 0 36 0 37 0 38 0 90 0 91 0 91 5 91 5 92 0 93 0 94 0 95 0 •?6 0 

### 97 0 93 0 99 0 100 0 101 0 102 0 103 0 104 0 105 0 105 0 107 0 103 0 109 7 110 0 111 0 112 0 113 0 114 0 115 0 115 0 117 0 113 0 119 0 120 0 yo u hav e othe r part s o r rack s solution ? ( Y o r M) " t o calculate "

THE NGOT O 46 0 "D o yo u hav e othe r solution s t o calculate ? ( Y o r N ) PRINT TA3(15) ; "you r solutio M i s no t 1005 5 efficient. " PRINT:PRINT TAB(10);"T o do this , divid e th e tim e b ythe efficienc yexpres s a decimal. " 'PRISIT : PRINT TAB(10);"D o PRINT TAB(15);"fo r thi s INPU T Z 3 I F Z3="Y " O

R ZS="v " PRINT:PRINT TAB(10 ) INPU T Z 3 I F Z3="Y " O

R ZS="y " THENGOT O 40 0 PRIMT:PRINT TA3(10);"D o yo u wan t t o us e one o f the othe r options ? ( Y o r N ) INPU T Z S I F Z3="Y " O

R Z$="y " THE NGOT O 10 0 EN D RE M - CALCULAT E PLATIN G TIM E - BARRE L WOR K RE M - O R RAC K WOR

K O F UNKNOW

NARE A CL S PRINT : PRINT : PRINT -ZZ^i.jr---

- PRINT TA3(23);"Platin g time'calculation " PRINT:PRIN r TAB(10);"I t wil l estimat e th e prope r PRINT TABOO ) ; "thicknes s neede d whe n th e are a i s

platin g time fo r an y n o t known. " PRIN T TAB(10);"I t may ba^xise dfo r

stamping s o r

barre l plate dparts. " "Yo u mus t

know: " 

### "The "bas e meta l t o b e plated " "The weigh t i n ounce s o f a par t o r a numbe r o f parts " "o r the averag e dimensio n an d length. " "o f th e piece s t o b

e plated. " "The averag e curren t densit yneede d fo r goo d plating. "

1
. stamping s or 2
. scre w machin e parts? " prope r number":INPUT Z "Wrong entry . Tr yagain
. ":G0T 0 96 0 PRINT-.PRIN

T TABOO ) PRINT:PRINT TAB(15 ) PRINT:PRINT TAB(15 ) PRINT:PRINT TAB(15 ) PRINT:PRINT TAB(15 ) PRINT:PRINT TAB(15 ) FO R 1= 1 TO 5000:NEX T CL S PRINT:PRINT:PRINT PRIN T TAB(IO);"Ar e part s PRINT TAB(15);"Ente r th e I F Z< 1 O

R Z> 2 THE NPRIN

T I F Z= 2 THE NGOT O 150 0 CL S PRIN T TA8(10);"Wha t i s th e bas e metal? " PRINT TA3(15);"1
. Aluminum ; 2
. Steel ; 3

- Copper ; PRINT:PRINT TAB(10);"Ente r th e prope r number. " INPU T Z I FZ< 1 O

RZ> 4 THE

N PRINTT^ron g entry
. Tr y agai n 

### I F Z = 1 THE NW=1. 6 X

. I ? Z= 2 THE

NW=4. 5 I F Z= 3 THE NW=5 ! I F Z= 4 THE NW=4. 8 PRINT:PRINT TAB(10);"Ente r th e approximat e thicknes s o f th e stock " PRINT TABOO) ; "i n inches. " PRIN T TA3O.0);"D o no t us e fractions
. Us e decimals. " INPU T T1 PRIMT:?RINT TA3(10);"Ente r the weigh t in ounce s o f the piec e o r piece s PRIN T TAB(10);"D o no t us e fractions
. Us e decimals. " INPU T '.7 1 S1='.71/(T1*W ) PRINT:PRINT "Th

e are a i s ";S1; " squar e inche s pe r piece/pieces. " S=S1/14 4 PRINT : PRIN T TABOO) ; "V/ha t meta l i s t o b e plated? " .Bras s
":G0T 0 101 0 

# 7

"fP.1 6



### 121 0 PRIN

T TABOO ) ; "Ente r ful l nam e i n capita l letters. " 122 0 INPU

T 3 $ 123 0 GOS' J 3 320 0 12* 0 ?RIMT:PRINT TAB(10);"Ente r th e require d plat e thicknes s i n inche s e.g . . 0 o r .0002 " I25 0 INPU

T T 125 0 ?RIMT:PRINT TAB(10);"Ente r the averag e curren t densit yt o b e used. " 127 0 PR I I

T TABOO) ; "Ente r a s amp s pe r squar e foot. " 123 0 INPU

T P
• : : 

### " 0 R-5* ? 1 ) 0 R1=R*16/W 1 •;'! 0 ?RINT:PRINT TAB(10) ; "Platin g wil l requir e ";R; " ampere s pe r piece/pieces
. 172 0 PRIN

T TABOO) ; "o r ";R1; " ampere s pe r poun d o f parts. " 1"5 0 M=(T*1000)*D*60/ P !34 0 ?RINT:?RINT TAB(10);"A t ";P; " ampere s pe r squar e foot " 155 0 PRIN

T TAB(10) ; "an

d 100? * efficiency, " 156 0 PRIN

T TABOO) ; "i t wil l rpqnirp ";M; " minute s t o deposit " 157 0 PRIN

T TABOO) ; " a thicknes s o f ";T; " inches. " 133 0 PRINT-PRIN

T TAB(10);"Yo u wil l hav e t o adjus t thi s tim e if " 139 0 PRIN

T TAB(10 ) ; "you r solutio n i s no t 1005 ? efficient. " '40 0 PRINT:PRINT TA3(10);"T o d o this , divid e th e tim e b yth e efficiency " 141 0 PRIN

T TABOO ) ; "expresse d a s a decimal. " 142 0 ?RINT:PRINT TA3(10);"D o yo u hav e othe r part s t o calculate " 143 0 PRIM T TABOO) ; "i n thi s way ? ( Y o r tl) " 144 0 INPU

T Z 3 145 0 I F Z$="Y " O

R Z$=»y " THE NGOT O 96 0 145 0 GOT O 70 0 150 0 PRINT:PRINT "Ente r th e averag e dimension s o f th e piec e a s a decimal. " 151 0 PRINT:PRINT"I f th e piec e i s round , ente r the averag e diameter. " 152 0 PRINT:PRINT "I f the piec e i s squar e o r hexagonal " 153 0 PRIMT "ente r the widt h o f on e face. " 154 0 ?RINT:PRIN

T "I s piec e round , squar e o r hexagonal ? (R,S,H)":INPUT C $ "!55 0 PRINT : ?RINT"Ente r dimension " : INPUT V/ 2 155 0 PRINT:PRINT "Ente r length":INPUT L 157 0 I ? 03="R " THEN.S1=W2*3.142* L •:?3 0 I F C3="3 " THE NS1=W2*4* L 159 0 I F C3="H " THE NS1=W2*6* L 150 0 PRINT:PRIN

T "The are a o f eac h piec e i s ";S1; " squar e inches. " 161 0 S=31/14 4 152 0 PRINT:PRINT "Ente r th e meta l t o be plated. " 155 0 ?RINT:PRIN

T TAB(10);"Ente r the ful l nam e i n capita l letters. " 154 0 INPU

T 3 3 154 5 GOSU B 320 0 'GS T DAT A 155 0 PRINT:PRIN

T TAB(10);"Ente r the require d plat e thicknes s in inche s e.g . .0 0 or .0002 " 155 0 INPU

T T 157 0 PRINT:PRIN

T TAB(10);"Ente r the average'curren t densit yt o b e used. " 163 0 PRIN

T TABOO ) ; "Ente r a s amD S pe r squar e foot. " 159 0 INPU

T P 170 0 R=3* P 171 0 PRINT:?RIN

T TAB(10);"Platin g wil l requir e ";R; » amp s pe r piece. " 172 0 M=(T*1000)*D*60/ P 173 0 PRIMT:PRIN

T TAB(10);"A t ";P; " ampere s De r squar e foot " IM O PRINT:PRIN

T TAB(10);"and 100 3 efficiencv, " 175 0 ?Ri:!T:?RIN

T TAB(10);"i t wil l requir e ";M; " minute s t o deposit " 176 0 PRINT:PRIN

T TAB(10);" a thicknes s o f ";T; " inches. " 1^7 0 PRIMT:PRIMT TAB(10);"Yo u wil l hav e t o adjus t thi s tim e if " " ' r 7 

### 3 0 PRI>-12 TA3(10) : "you r solutio n i s no t 100 3 efficient
. ~~ 179 0 PRIMT:PRIN

T TAB(10);"T o do this , divid e th e tim e b yth e efficiency, " JO O PRSIT

TABOO) ; "expresse d a s a decimal.. "P.1 7

131 0 PRIMT:PRIM T "Do.yo u hav e othe r part s t o calculate " 132 0 PRIN T TAB(10);"i n thi s way?( Y o r N) " 13.5 0 INPU T Z S 

### 134 0 I ? "3="Y " O R Z$="y " THE NGOT O 150 0 1 3 = 0 SSZ

70 0 19ZD SSI

ELATIN GTHICKNES S CALCULATIO N 

### 191 0 Z Z 192 0 ZZ Z TA3(25) ; "Platin g thicknes s o r weigh t calculation " 193 0 ?r.. . IT : PRINT TABOO) ; "I t wil l extimat e the averag e thicknes s o r coatin g " 19- 0 PRIN

T TA3(10);"weigh t fo r an yse t o f platin g conditions. " 195 0 PRINT:PRINT TAB(10);"Yo u mus t know: " 196 0 PRINT:PRINT TAB(15);"Platin g tim e i n minutes " 197 0 PRINT:PRINT TAB(15);"Averag e curren t densit yi n amps/squar e foot " 193 0 ?RINr:?RINT TAB(15);"Wha t meta l i s being plated. " 199 0 PRINT:?RINT TAB(10); "Ente r ful l name o f meta l i ncapita l letters. " 200 0 INPU

T 3 3 20I O G0SU 3 320 0 'GE T DAT7T- i

- 4Si S 202 0 ?RINT:?R:M T TAB(10);"Ente r th e platin g tim e i n minutes " 203 0 INPUT I 

### 204 0 PRINT:PRIN T TAB(10);"Ente r th e curren t densit yi n ASF " 2 0 4 5 I :?U

T ? 205 0 T=((M/60)*(P/D)/1000 ) 206 0 PRINT:PRIN T "Unde r th e condition s given , th e thicknes s wil l b e " ; 206 5 PRIN T USIN G ".######» • ;T ; 205 5 PRIN T " inches. " 207 0 v/ 5 = T*3*100 0 203 0 PRIMT:PRIN T " Acoatin g o f " ; 203 1 PRIN T USIN G ".######» » ;T ; 203 2 PRIN T " inche s wil l weig h " ; V/3; " ounce s pe r squar e foot. " 209 0 PRIN T .-PRIN

T "Thes e figure s ar e base d o n 100 3 efficiency. " 210 0 ?RINT:PRIN T "I f you r solutio n i s no t 100 3 efficient, " 211 0 PRIN T TA3(10);"the ywil l hav e t o b e adjusted. " 212 3 PRINT:PRIN T "T o d o this , multipl yb yth e efficiency, " 215 0 PRIM T "expresse d a s a decimal. " 214 0 PRINT:PRIN T TAB(10);"D o yo u hav e mor e calculations " 215 0 PRIM T T;.3(10);"o f thi s kin d t o do ? ( Y o r II) " 216 0 INPU T 1 3 •217 0 • I ? :3=".' " O

RZ$="y " THE

M GOT O 198 0 Z13 0 ;)T 0 70 : 

### 520 0 RT M PR0J-RA

M T O GE T DATA — 5 2'' 0 REA D A 3
. 3 C D ---'

- 522 0 I F A3="?399 " GOT O 827 0 323 0 I F AS=E 3 THE NGOT O 825 0 324 0 GOT O 321 0 325 0 RESTOR E 325 0 RETUR N 32 T 

### 0 PRIM T TA3(10);"Yo u hav e mad e a n imorooe r entry. " 323 0 PRIN T TA3(10);"W e canno t fin d th e neede d data. " 3 2 9 0 PRIN T ?A3(10);"W e wil l prin t th e entir e lis t s o yo u can " 350 0 PRUI T TA3(10);"se e ho w t o mak e th e entr yproperly. " 35: 0 ?R:;T:?RIN T 

### TABOO) ; "I f th e meta l yo u wan t i s no t on th e list, " 3 5 2 0 PRIN T TA3(10);"w e canno t hel p you. " Z : 

### :" 0 P'TM T i;3(10);'T n tha t case , typ e STO P t o en d th e program. " J;-"- 0 -y~. 1 = 1 T O 3000 : NEX T I 

## rz o :L S Sr 0 RZ5TOR 3 Z 5 3 SPD A3,3,C, D ,{ 7 ) : 

### 5j 0 I F 43="9999 " THE NGOT O 342 0 •- ? J40 0 PRIN T Tn3(20);"A S " ' 

### IPP.1 8



# sLL^PfStir.
.3 4 j O FRZI T TAB(20 ) j^-'A S 

### -TfT~j;: 3 3 53

3 " •12 0 PRINT "Ente r

STO P o r th e desire dmeta l exactl y a s show n i n th e lis t above ' TZ.'.-M T 3 5 •:;d Z? 53<>"ST0P " THE NREST0RE:G0T 0 820 0 -:1 0 PRIS T T\B(10);"Sorry
. Yo u ca n ad d th e neede d dat a t o th e " SSI PRZ. T TABOO) ; "en d o f th

e dat a lis t t o expan d th e program. " :EN D Zli D 0,-Z

AANTIMONY,.56 , .0018,10. 4 •47 0 DAT

AARSENIC,.47,.00213,14. 4 043 O DAT

ACADMIUM,.71,.00139,9.7 3 "Z9 0 DAT

ACHROMIUM , . 5 9 , . 0016 9 ,5 1
. 3 3 50 0 DAT

AC O SALT(OUS),.74,.00135,19. 0 :51 0 DAT

ACOPPER(CYANIDE),.74,.00134,8.8 9 ?52 0 DAT

A00PPSR(ACID),.74,.OO134,17. 8 i5" D DAT

AGCLD(+1),1.47,.00063,5. 2 5 5 1 0 DAT

AGOLD(+5),1.47,.00068,13. 6 •53 0 DAT

AINDIUM,.56,.00182,12. 0 •56 0 DAT

AIRON(+2),.65,-00153,17. 9 :3 T 

### 0 DAT

ALEAD,.94,.00106,6. 9 35 0 DAT ANICKEL,.74,.00135,19. 0 \H° 59 0 DAT APALLADIUM,.36,.00115,13. 5

• 50 0 D AT

AP L ATINUM,1.60,.00062,27. 3 •51 0 DAT

ARHODIUM, . 95,
. 00106,22. 9 / •' . •52 0 DAT

ASILVER,.79,.00126,5. 2 753 0 DAT

ATIN(+2),.61,.00164,7. 8 -.57 0 DAT

ATIN(h4),.6 1 ,.00164,15. 6 $** 3 55 0 DAT

AZINC,.59,-00163,14. 3 *^' 5 5 5 0 DAT

A999 9 5:0 0 RE NLIS T OF'VARIABLE S ••01 0 RE M A 3 - PLATIN G SOLUTIO

NI NFIL E Z'2D RE M 3 - WEIGH T O F 0.001"-I M FILE * •} 3 0 ?X.-\ C - THICKNES S O F 1 O Z I NFIL E •M O RE M D - AM

O HOUR S FO

R 0.001 " PE R S Q F

T I NFILE ' O? 0 R I ! 0 1 - INPU

T DIMENSIO

NFO R BA R STOC K

- >3 0 ?.£'• ! Z - TEMPORAR Y VARIABL E FO

R NUMERI C INPUT

. : 

### J 7 0 RI M Z 3 - DITTO ALPHANUMERI C INPU T ; 

### T-3 0 RI M 3 3 - INPU

T PLATIN

G SOLUTIO

NUSE D -09 0 RI M Cl

- INPU

T SHAP E O F BA

R STOC K .••'.O O RI M T - INPU

T REQUIRE D THICKNES S O R OUTPU T PROGRA

M CALCULATE D THICKNES S •'1 0 RI.- ! T1 - INPU

T STOC K THICKNES S - STAMPING S
• 1 

### 2 0 RI M S - SURFAC E AREAI NS Q F T - INPU

T O R CALCULATE D 913 0 RI M 3 1 - SURFAC E ARE AI NS Q INCHES ' ."•14 0 RI M ? - AVERAG E CURRENT DENSIT Y - INPU T OR CALCULATE D -•5 0 RI M R - AMPERE S REQUIRE D PE R RAC K O R PE R PAR T ->3T ) RI M R1 - DITT O PE R POUN D •i-7 0 RI M 1 - PLATIN G TIM E INMINUTE S INPU T O R CALCULATE D }'S RI M .

7 - DENSITY O F SHEE T META L I NOZ/CUBI C INC H "S O RI M '.7

1 - WEIGHT O F PIEC E O R PISCE S INPU

T 37. 0 RE M V/

2 - DIMENSIO

NO F BA

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T 9
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5 - WEIGH T O F PLATE D META L CALCULATE D 9.. 0 RI M L - LENGTH O F PART - BA R STOC K O

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/ /P.1 9

Attachmen t 3 . Exampl e Calculation s Provide db y MR I



# SP.2 0

EXAMPL E O F PRODUCTION RAT E CALCULATION S FO R HAR D CHROMIU

M PLATIN GAPPLICATION S
Mediu m mode l plan t parameter s Ampere-hour s pe r yea r = 42x1 0 Mode l tank s = 1 @ (4.0,4.0,10.0 )

2 @ (12.0,4.0,6.0 ) 1 @ (25.0,3.0,6.0 ) Operatin g tim

e = 3,50 0 hours/yea r Percen t time electrode s energize d= 7 0 Paramete r value s fo r hydrauli c cylinder s (Attachmen t 1 ) Curren t densit y

= 28 8 ampere s pe r squar e foqt Platin g time a t curren t densit y o f 28 8 A/f t = 2 hour s Plat e thicknes s = 1 mi l 2 Surfac e are a o f hydrauli c cylinde r = 8. 7 f t = 1,25 0 i n* Ampere-hou r requirement s pe r squar e foo t (28 8 A/ft 2 )(2. 0 h ) = 57 6 A«h/ft 2 Mediu m mode l plan t productio nrat e

(42xl0 6 A«h/yr)(ft 2 /57 6 A»h ) = 72,90 0 ft 2 /y r (72,90 0 ft 2 /yr)(part/8. 7 ft 2 ) = 8,38 0 parts/y r Productio nrat e assumption s (Tabl e 1 ) Maximu m tank capacitie s fo r mediu m mode l plan t (4.0,4.0,10.0 ) tank hold s 1 8 f t o r 2 cylinder s 2 tank s @ (12.0,4.0,6.0 ) hol d3 2 f t or. 3 cylinder s (25.0,3.0,6.0 ) tan

k hold s 5 0 f t o r 5 cylinde r Maximu m capacit y

fo r al l tank s = 1 3 cylinders/2 h= 6. 5 cylinders/ h Productio nrat e pe r hou r

[8,38 0 cylinders/yrl[ (3i50 0 h/ ^ r)(o>7o) ] = 3. 4 cylinders/ h Therefore , maximu

m capacit y

i s no t exceede dan

dproductio nrat e o f 3. 4 cylinders/ hshoul db e used . Inth e even t tha t anend-produc t productio nrat e i s highe r tha nthe maximu m capacit y

value s o f th e platin g tanks , the nth e productio nrat e shoul dbe base do nth e maximu

m tota l tank capacity .

•Base donSectio n11 4 data .



# ilP.2 1

EXAMPL E O

F PRODUCTIO

N RAT E CALCULATION S FO RDECORATIV

E CHROMIU M PLATIN GAPPLICATION S Mediu m mode l plan t parameter s Ampere-hour s pe r yea r = 12.0x10 ° Mode l tank s = 2 @ (12.0,3.5,6.0 ) Operating tim

e = 4,00 0 h/y

r Percen t tim

e electrode s energized= 6 0 percen t Paramete r value s fo r ratchet s (Attachmen t 1 ) Curren t density

= 6 0 ampere s pe r squar e foqt Platin g tim e at current densit y o f 6 0 A/f t = 4 minute s = 0.06 7 h Platin g thicknes s = 10-2 0 mils? * Surfac e are a o f fauce t = 2 5 squar e inche s Calculatio

no f plat e thicknes s for ratchet s

Electrochemica l equivalen t 51 8 .. . assumin g cathode efficienc y = 2 o f 1 0 percen t mil-f t
( ^i8_^h ) ( ^t! K ^ ^ ) m 12Q9 Bir i „ 0#00 8 mi l mil-f t o u M

U
Ub / nplat e thicknes s Ampere-hour s requiremen t per squar e foo t

Mediu m mode l plant productio nrat e
(12.0xl0 6 Mj^ft^ ) = 3.0XIO 6 ft 2 /yr

2 (3.0xl0 6 ft 2 /yr) ( P a r t )( 1 4 4 ] n - ) = I7.0xl0 6 rachets/y r 2 5 in . f t

*Note : Th

e plat e thicknes s appear s t o b e incorrect .



## X/oP.2 2

Productio nrat e assumption s Numbe r o f rack s pe r hou r fo r on e tan k Mode l tank i s 1 2 fee t lon g Tabl e 2 dat a - 1 rac k ever y 2 fee t o f tank lengt h Therefore , (1 2 ft)( l rack/ 2 ft ) = 6 rack s intan k a t on e tim

e o r 6 plating cell s pe r tan k Plating time = 4 minute s

4 min/ 6 cell s = 0.6 7 mi no r 4 0 seconds/cel l I.e. , a rac k i s remove dfro m the tan

k every 4 0 second s Therefore , ( 1 rack/4 0 s)(6 0 s/ 1 min)(6 0 min/ 1 h ) = 9 0 racks/ hfro m on e tan

k Mediu m mode l plan t ha s tw

o identica l tank s Therefore , (9 0 racks/h/tank)( 2 tanks ) = 18 0 racks/ h Squar e footag e pe r rac k

[3.0xl0 6 ftVyr][(4,000^(0.60) 1 = l ' 2S0 ft '

/h plan t % tim

e operatin g electrode s tim e energize d (1,25 0 ft 2 /h)( l h/18 0 rack ) = 7. 0 ft 2 /rac k



## J/P.2 3

Attachmen t 4 . Compute r Program

Use db y JAC A Corporatio nt o Determin e Uni t Platin g Cost s



## J*-B y LAWRENCE J

, Consultan t There are three basic systems. Here's how they work and here's a computerprogram that lets you use yourcomputerto do the calculations... DURNE Y
A successful cost-calculatin g proce dure , like an

y accounting procedure , depends upon carefu

l attentio n to a multitude o f

details . Atthe hear

to f an y suc h calculatio n is the nee

d fo r accurat e knowledge o f

various oper ating costs . Therefor

e a casua l ap proac h to handling , recordin

g an d al locating expenditures is notonly inexcusable , i

ti s self destructive . Ther e ar e three basic cost-cal culating systems : The simplestsyste

m require s tha t yo u separat e laboran d it s associated costs—vacation pay , hospitalization , socia l securit y payment

s an d s o on — fro m al l othercosts . Thi s informa tio n is the n translated into hourl

y la borcosts fo

rvarious labo rcategor ies , suc h a s rackcrs' , machin e operators , packer

s an d s o on . Usin g thi s system , the sho p man age rdetermines the hour

s o f various kinds o f laborrequire

d fora give

n jo b an H divides by the numbe ro f part s o rpound s plated to fin d hi s cost . Thi s figur

e i s multiplied b

y a n overhea d percentage to establish the cos to f overhea d forthis particula

r job . The n thes e tw o costs ar

e added t o determin

e tota l processing cost . The tota l processing cos ti

s the n multiplied b

y afacto rtha

ttakes int o accountexpected profi

tplus asales man' s commission , if

on e i s paid , t o obtai n aselling price . The facto r(F) is : F=l(l-P-C ) wher e Pis the expected profi tpercentage an

d C i s th e commissio n paid , bot h expresse

d a s decimals , (e.g. , 1 0 pc texpected profi

ti s 0.10) . This syste m work s wel l fo rashop tha ti s ver y limited i

n scop e an

d variety , e.g. , asho p doin g onl y barre l zinc plating . A mor e comple x shop would requir e additiona

l calculations t

o ac coun tfo rth e varyin g cost s o f metals . Thi s would be necessar

y i n a sho p platin g copper, nickel , chromiu

m an d gold , fo rexample . Whe n this i s th

e case , th

e shop manage rmus tno tonl y separat

e his labo rcosts , bu

tmus tseparat e the cost s o f anode s an d platin g salt s fro m al l othercosts . The overhea

d i s agai n calculated , as previously . (Overhea d wil l now be alowerpercentag e tha n in the firs tsystem , since meta

l cos t is no tinclude d wit h overhead) . PRODUCT ; FINISHIN G 7 9

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