Electroplating Balls – Getting stuck in baskets

On 8th of November 2021, Cherie Fox form Orrcon informed us that electroplating balls were... "becoming stuck in our baskets, and not breaking down as they normally would.
As they become wedged against each other, affects the current around the balls."

10NOV21: In LS words...
"Part of our (internal) discussions yesterday was to digest some modification concepts to our current casting process with specific regard to reduce flashing. We have some preliminary design considerations on the table already but as with all R&D projects, combined with the day to day work load this takes time so we cannot foresee a quick fix against a change in mould design. Reduction of flashing in the short term will be resultant from a higher level of preventative maintenance and stricter controls on casting process. We have already implemented tighter visual inspection of cast product during the break off phase and are quarantining any product that has an unacceptable level of flashing. We are exploring other options such as different die coat and more finite temperature control. All which we believe will see a reduction in the size/qty of flashing."

and LS on 23NOV21....
"I trust that your Gal Plant Manager and staff are already seeing a significant improvement on the amount of flashing present on product that has been supplied in the last 2 weeks. CAA will utilise the time gained against the reduction in tonnage to schedule preventative maintenance and we have implemented a structured periodic engineering rebuild of moulds to ensure that with best foundry practice, productivity and quality of product can be maintained at all times against an offtake of 40 metric tonnes."

The steps that were not carried out which lead to the flashing were:
Lack of scheduled preventative maintenance against extremely heavy production load. Most likely also attributable to excessive high metal temp. Also very attributable to operators not maintaining high casting standards. Everyone is guilty, it has been an issue that has been discussed for a long time. This complain tis the impetus to improve.

Maintenance Scheduling: We will pull out one set of dies at a time and give to CDQ to undertake periodic rebuild of each mould. Closer observation of wear and tear will determine frequency of rebuild. Plus 2 x monthly scheduled coating and tension adjustment. LS ordered a crucible that will accommodate a thermocouple which will connect to a digital display so that the operator can readily see bath temp. We also now have reject buckets where the crew will remove product that has excessive flashing. The product quality is heavily reliant of supervision and inspection of product and therefore plant but also the operators must speak up immediately upon witnessing any increase of flashing on product.

We will undertake some mould design R&D to try and further eliminate flashing. This is not only important for current casting process but possibly for ultimate mould design for the Big Balls Project should it ever get off the ground.

Damo has addressed the staff regarding higher levels of care with casting. We will insert on agenda for next toolbox talk for team awareness and stress the importance and possible impact to business etc.

Early SEP22: LS and SP attended meeting at Orrocon. They discussed this issue. They said that quality of the product has increased significantly and that there had been no lodged complaints from there staff since CAA have implemented a more regimented maintenance program on the ball casting moulds.

Verification –Have Orrcon made further complaints? No further complaints as of early SEP22
Reported by –BL
Closed by –BL
Date closed –September 14, 2022