Scope of this guide
Intermediate version: symptom-to-cause triage with the confirm-by column — find the variable, run one change, verify.
This series answers a top recurring question from finishing forums with platingclub line practice. Parameters are industry-standard starting ranges — confirm against your supplier TDS.
Triage: symptom → confirm → first move
| Observation | Likely cause | Confirm by | First move |
|---|---|---|---|
| Thickness below spec on time | Dose under-counted | Amp-min per kg log | Recalculate by weight, not barrel count |
| Outer parts thicker | Normal barrel gradient | Sample by position | Extend cycle; sample per spec points |
| Cycle drifting longer | Contact resistance rising | Dangler tips check | Clean/replace danglers |
| Burns after time extension | CD ceiling reached | Burn map by position | Split load or lower current |
| Thickness scatter widens | Load size variance | Weigh-in records | Standardise load weight |
Engineer notes
- One variable per corrective action; verify by the confirm-by column.
- Records beat memory: log every trial on the tank card.
- Escalate when two consecutive actions fail — that is a senior call.
Safety: barrels, hoists and live bus bars share one line. Heat gloves for loads, lock-out before contact service, and never reach into a running barrel.
FAQ
Parts at the barrel door plate thicker — fix?
Normal gradient. Extend time and sample to spec points; add a door baffle if it exceeds range.
What raises cycle time without spec change?
Contact resistance, bath chemistry drift, colder bath. Check in that order.
How do I build a thickness curve?
Run timed pulls at 5 points across the cycle; gauge and plot. One curve per part family per bath.