Kevin L. Klink, P.E.

1. Tools and Techniques for Optimizing Metal Finishing Process/Environmental MA Metal Finishing Forum Kevin L. Klink, P.E.

2. Overview • Integrated Process/Environmental Planning/Design • Water and Chemical Recovery and Reuse • Software Tools for Improved Decisionmaking and Implementation • Life Cycle Information Management • Life Cycle Project Improvement • Supply Chain Impacts

3. PROCESS/ENVIRONMENTAL PROJECTS

4. Opportunity to Influence Project 100% Advanced Planning Manufacturing Optimization Maximum project cost control is gained through effective early planning and engineering 80% Conceptual Design Preliminary Total Capital Cost design 60% Ability to Influence Total Capital Cost Detailed design 40% 100% Construction and Equipment Installation 20% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Project Timeline

5. Project Value is Maximized Through Systematic Planning and Implementation • Plan for adequate and flexible systems that meet current needs & can be easily modified to meet anticipated contingent/future scenarios • Design efficient systems that maximize product quality and yield and minimize waste • Implement useful information systems and documentation • Meet/exceed goals • Avoid constraints

6. WATER AND CHEMICAL RECOVERY AND REUSE

7. Water and Chemical Recovery and Reuse Drivers • Reduce wastes • Reduce solution contaminants and constituent variations -- improve quality and performance of process solutions and rinse waters • Reduce chemical and water use Constraints • Buildup of undesirable contaminants • Incremental systems that will not be properly operated and maintained

8. Metal Finishing Process Water Flow Schematic Drag-in Drag-out Drag-out Drag-out Process Bath Rinse Tank 1 Rinse Tank 2 Batch Discharge to Waste Treatment Make-up Water Make-up Water Continuous Discharge to Waste Treatment Continuous Discharge to Waste Treatment Make-up Chemistry

9. Chemicals/Water Separation System Process Solution Maintenance and RinseWater Recycling Drag-in Drag-out Drag-out Drag-out Process Bath Rinse Tank 1 Rinse Tank 2 Purified Rinse Water (Low TDS) Purified Water Water Recycle System Maintenance Purification Make-Up Water Impurities Purified Chemicals

10. A Balance of Integrated Pollution Prevention and Pollution Control Provides Lowest Life Cycle Cost Increasing costs All pollution control All pollution Prevention 0 0.25 0.5 0.75 1 Increasing pollution prevention

11. SOFTWARE TOOLS FOR PROCESS/ENVIRONMENTAL IMPROVEMENT

12. Navy Demonstrated Success with Off-the-Shelf Anodizing Process Controls

13. Computerized Process Recipes, Monitoring, Control, and Verification Reports Improve Processing

14. Process Modeling Provides Estimates of Facility Flow Balance, Energy, Material Use, and Annual Costs

15. Process Modeling Provides Estimates of Process Flow Balance, Energy, Material Use, and Annual Costs

16. Process Cost Report Itemizes Nine Cost Categories for Each Process

17. Modeling Production Ranges Produces Ranges for Flows, Energy, Material Use, and Annual Costs

18. Process Model Data Can be Exported to Tankline Spreadsheets

19. Chemical Usage Export to MS EXCEL Provides Basis for Chemical Consumption and Inventory

20. Use of Data Management Software Provides Automatic Trend Plotting and Statistical Calculations

21. Linking Photos and Documents Into Data Software Enhances Value of Information

22. Data Management System Software Implements Selected Automatic Responses to Data Results

23. LIFE CYCLE INFORMATION MANAGEMENT

24. DATA DATA DATA DATA Planning Provides Awareness of Data Generation Over Project Life Cycle Design Construction Facility Management Planning 18 months 2 years 20 years 1 year

25. A Data Warehouse Enhances Project Lifecycle Information Management and Use

26. Early Data Input Maximizes Data Utility Planning Planning

27. Data Warehouse Delivers Benefits Over the Entire Lifecycle Startup Commissioning O&M Planning Construction Design

28. Design Files • Software Input/output • IntranetO&M Manual • O&M Logs, Notes Access Vast Range of Data On Fixed PC or Laptop, Tablet or Pocket PC

29. Benefits of State of the Art Project Data Systems • Data is more accessible and reliable • Accurate, reusable information for project lifecycle • Improve project understanding and communications • Reduces cost and accelerates project delivery time • Lower risk for changes, conflicts, errors and omissions • Increased staff productivity due to easier access & availability of data • Improved record-keeping and cross-referencing

30. Integrated Process Planning and Information Tools Produces Excellent Benefits • Establish requirements, goals, constraints • Understand impacts of production ranges on process systems and support systems • Plan efficient life cycle information management systems • Maximize opportunity to incorporate productive, efficient, lean, profitable systems • Initiate effective life cycle implementation and mechanisms for continuous improvement • Improve project delivery approach, information sharing, efficiency, ability to control project, and ability to integrate beneficial technique and technology

31. Supply Chain Considerations Motivation • Respond to Requirements • Opportunity for Improvement Impacts • Efficiency • Quality • Profitability