Even though the hard chrome bath is relatively easy to maintain, the overall process is quite complicated, and specialized training is needed to be successful.
Eric Svenson Sr.This is because of complex issues involving the following items:
- Preplate requirements for grinding
- Heat treating and stress relief
- Surface finishing requirements for polishing
- Substrate inspection for defects prior to plating
- Anode requirements and their design
- Anode positioning and spacing relative to the cathode
- Fixture design for best chrome distribution and electrical conductivity
- Surface cleaning requirements to remove oils and oxides
- Stop-off sometimes needed for unplated areas
- Activation methods and reverse etching times for different base metals
- Plating time calculations for obtaining the desired chrome thickness
- Variations in the rectifier DC waveforms
- Requirements for controlling bath impurities
- Environmental and worker safety requirements
Understanding the entire process, along with the why, is essential for hard chrome plating operations. An in-depth knowledge is required because it involves the quality of work produced, the productivity of the operation, compliance with a myriad of regulations, and ultimately the company’s bottom line. This is especially true given that a large portion of hard chrome work involves critical applications like aviation, transportation, automotive, fluid power, agriculture, mining, railroad, and defense. All of these industries, among many others, are vital to the U.S.’s success as a nation.
Having properly trained employees help considerably when issues arise over things like bath chemistry, operating conditions, part surface irregularities, equipment performance, and electrical problems. These can be addressed and solved quickly with a skilled and knowledgeable workforce.
Unfortunately, there is a void in some operations that lack the newer technology that is available. This costs these shops both time and expense when having to hire outside experts or relying on vendors to solve the problem. Meanwhile, it continues to escalate and damage the business. This also prevents production expansions and even delays them from meeting customer delivery requirements.
The Training Problem
Worker turnover is a major problem facing both job and captive hard chrome operations. Many shops have a hard time keeping skilled employees. This leads to decreased throughput and increased rejects. These rejects require stripping and refinishing, which can triple production costs.
The Work Institute estimates that some 45 million U.S. workers have voluntarily left their job in 2022 to seek a better opportunity. But 78% of this could have been prevented by their employer. A lack of training is frequently the No. 1 reason for leaving. In contrast, those with an opportunity to expand their knowledge were much more likely to stay with the company and advance their career.
Plating companies need updated processes and technical skills. Yet, it becomes even more difficult for hard chrome platers to find and retain people with adequate knowledge about the process. This is why a formal training program has become so essential today; this applies to both new hires and seasoned professionals. It is also valuable to include cross-training of the various plating shop employees.
The overall hard chrome labor force typically includes job titles like shift foreman, lead plater, plating helper, engineering support, and ultimately the management team. Each of these positions requires a knowledge base relative to their job function. It is important the foreman, lead plater, and engineer fully understand the hard chrome process and all its complications.
Significant knowledge is lost when a critical employee or skilled worker quits or retires. This loss damages corporate profits because the labor gap results in a companywide lack of process knowledge that causes decreased product quality, production inefficiency, slower deliveries, and reduced profitability. At the same time, this increases liabilities and customer dissatisfaction.
Educational Opportunity
At Plating Resources, Inc., we have provided operator training for over 35 years, and most of this has been for OEMs that installed a new hard chrome system. Many of the students were workers without any previous plating experience, so we trained them from scratch. The success rate of this training has been excellent as these companies continued to grow and expand while producing hard chrome-plated parts of exceptional quality.
This encouraged us to develop a formal program we call “Hard Chrome University.” It is inclusive that it takes the student through all aspects of the science and includes topics on:
- What is chrome, why do we use it, and how is it applied?
- All of the technical aspects outlined above under ‘Knowledge is Important.’
- The equipment components used and their maintenance requirements
- Identifying, correcting, and preventing plating defects
- Providing various techniques for special applications
- Improving production efficiency and throughput
- Plating bath and process solution control and analysis
- Environmental protection and worker safety for the plating shop
- Obtaining and maintaining sustainability for hard chrome operations
The typical timespan when using our Hard Chrome University program is about 10-15 days depending upon the particular requirements. It includes a mix of classroom instruction and hands-on experience using the customer’s equipment while plating their parts. We can also include a testing program where the students receive a certificate of completion.
Shorter versions of this training course can also be provided that focus on key problem areas. This program was later revised to include training for existing operations and companies wanting to increase their knowledge base or improve their efficiency and throughput. This is done at the user’s facility using the existing equipment and processes. The goal is to build on their strengths while also filling any technical gaps that may exist.
The Hard Chrome University training program includes a detailed book that covers every topic relative to the process. It is a great reference tool that becomes invaluable for solving future technical problems on the spot.
This is available to any company wanting to improve productivity and product quality or reinforce its technology base. We believe that profitability begins with having a well-trained labor force and adequate technical support. The knowledge provided expands the worker's awareness and prevents them from making basic yet costly mistakes.
We start by completing a survey of the plating operation, its processes, the equipment being used, and any existing plating issues. This enables us to target those areas, teach any lost skills, and provide the technology needed for success. Refresher courses and retraining are also available should a key employee retire or new hires come on board.
Direct Benefits of Hard Chrome University
Some of the direct benefits this training program provides include the following:
- Transfers critical process knowledge and technical skills
- Provides input on more efficient processes, equipment, and techniques
- Reduces the need for constant supervision
- Increases overall efficiency, production, and product quality
- Retains key employees and saves the cost of replacement and retraining
- Attracts new talent to where it is most needed
- Improves corporate profits, customer satisfaction, and market share
The Hard Chrome University program is only available in person. We believe that face-to-face and hands-on training is more effective in transferring this information to students than trying to do it online. Remember, every chrome plating line has room for improvement, which allows us to get them to their true plating potential.
Please contact Plating Resources, Inc., today to start and/or continue your Chrome Plating Education through the Hard Chrome University. Visit www.Plating.com
