Scope of this guide
Management version: this defect as cost and risk — the metrics, audit points and claim defence.
Series: finishing.com recurring questions answered with platingclub line practice. Parameters are industry-standard starting ranges — confirm against your supplier TDS.
Triage: symptom → confirm → first move
| Symptom | Likely root | Confirm by | First move |
|---|---|---|---|
| Plating where nothing should plate | Insulation chipped/cracked | Visual under load | Tag rack for rebuild |
| Thickness low on good positions | Current leaking to leaks elsewhere | Position thickness map | Find and retire leaking rack |
| Bath slowly heating / amps drift up | Leak paths multiplying | Amps vs parts trend | Audit racks, not the rectifier |
| Burn marks at rack tips | Contacts arcing | Tip condition photos | Dress contacts, check springs |
| Recurring after one rebuild | Rebuild quality or tape grade | By-rack failure history | Standardise tape spec |
Cost, metrics and defence
| Cost line | Driver | Metric | Lever |
|---|---|---|---|
| Energy | Current into leaks | Amps per good part | Weekly leak walk |
| Thickness escapes | Leak stealing current | Audit failure rate | Rack age ledger |
| Downtime | Emergency rebuilds | Planned vs emergency | Rebuild by cycles |
| Rectifier stress | Arcing contacts | Tip photos per audit | Tip dressing routine |
Engineer notes
- One variable per corrective action; verify with the confirm-by column.
- Records beat memory: log every trial on the tank card.
- Two failed actions in a row is a senior call — escalate with your log.
Safety: racks carry live current in acid and alkaline baths. Lock-out before touching, insulate tools, and never straddle two tanks with a rack.
FAQ
What does stray current cost?
Energy into leaks, thin deposits at packing, rectifier stress — all traceable to rack age.
Which audit finds leaks early?
The weekly under-load walk with photos; card completion is the KPI.
Rack fleet KPI?
Age distribution and rebuild count; a young fleet plates predictable.