The Hose and Cable assembly area was reorganized from 9 rows of stationary racking, to two sets of circular, vertical rotating racks. Employees rotate the rack to get the correct hose, pull the length off the reel onto the cutting station, then assemble with all the hardware needed close at hand. This is one of the many areas that have converted to a Two-bin vendor managed stock program. Hardware vendors stop in twice a week to check on what needs replenishment. Another change made was in the work flow of the assembly. The staff was re-trained so that each person completes a job from beginning to end. They used to each have a specific task then hand it off to the next person. The outcome of the lean improvements was that they were able to sell 15 tons of excess equipment, and gained enough space to build an additional (and sorely needed) testing station.

The team has to think creatively and be willing to accept change. Observing other successful businesses give them additional ideas. One example is working with suppliers to custom design packaging materials to reduce waste. Transport packaging is re-cycled and sent back to the supplier for future shipments. Sulzer Metco used to wait for vendors for service work. They decided to purchase their own equipment for tasks that they used to wait for. Be willing to re-design your product to reduce Non Value Added time.

The Analytical laboratory tests all incoming materials. Sulzer Metco has discerning customers in aerospace and automotive industries where integrity of the material is critical. Among the tests they conduct are phase determination, chemical composition, particle size, and flowability. The post-process lab is the Metallographic Laboratory. They determine if the coating is good and met the requirements. They have the technology to enhance any property needed, by carefully analyzing and balancing the tradeoffs of each property. For example, a coating that increases porosity is good for providing a surface that lubricants can cling to. However, porosity reduces resistance to corrosion. They achieve the different properties by varying the temperature, spraying distance and amount of powder. The coating is analyzed by encasing a sample in an epoxy, using vacuum impregnation to completely fill the surface. The Metallographic lab also checks the effects of powder morphology, which is impacted by the manufacturing process. Under high power magnification, you would want to see cracks in the coatings to allow for expansion and contraction. Think of this like expansion joints in bridges.

The metals manufacturing area is where the Thermal Barrier Coating (TBC) powders are made. Metals are mixed into a slurry, then the spray drying process produces composite powers to the size and composition requirements. These powders must be used with a high heat thermal process, to extend the life and add thermal protection to parts.

The Coating Solutions department develops the thermal spray processes, collaborating with other global units, to support new customers and new applications. Three techniques were demonstrated for the group. The HVOF, High Velocity Oxygen Fuel, method depends on kinetic energy generated by high flow, and high pressure. Speeds of the particle are in excess of Mach II, on the order of 600 meters / second. The Plasma Spray uses energy and gas to accelerate the spray material towards the substrate. It is the impact of the particles on the surface that forms the coating. The spray is heated to 30,000 C°, it exits the sprayer at 12,000 C° and hits the substrate at 3000 C°. The Wire combustion technology has been used for 100 years. A metal wire is fed into the plasma and the operating temperature is about 1700 C°. This is a hand held technique, most commonly used for bridge repair or corrosion resistance treatment.

The SumeBore Technology group develops custom applications for cylinder bore coating services. It is most commonly used in automotive applications. The RotaPlasma® technology is proprietary to Sulzer Metco. Wear resistant coatings with excellent frictional characteristics (or any desired property) can be applied to cylinder bores in engine blocks. Many of the clients are race car owners, but truck engine manufacturers can realize benefits as well. A truck can burn 7 - 8 gallons of oil a day. The effect of polishing the cylinder bores can reduce oil waste by 90%. Thus, there are cost benefits and environmental benefits to using this technology.

For more information about the company's technology, call 516-334-1300, or see the website, www.sulzermetco.com