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 |
|---|---|---|---|
| Oily films after cleaning | Concentration low or cold bath | Titration + thermometer | Rebalance to card range |
| Etched or dullened parts | Concentration too high / too hot | Weight-loss check | Dilute; verify card |
| Cleaning slow all day | Bath exhausted by oil load | Titration trend | Dump on trend, add overflow |
| Fumes/boiling at tank edge | Temperature over spec | Thermostat check | Cut heat; verify control |
| Stains after drying | Rinse drag-out from cleaner | Rinse conductivity | Counter-flow rinse audit |
Cost, metrics and defence
| Cost line | Driver | Metric | Lever |
|---|---|---|---|
| Chemicals | Dump by calendar not trend | Titration compliance | Dump on trend |
| Energy | Over-temperature habit | kWh vs set point | Thermostat verification |
| Rework downstream | Under-cleaning escapes | Water-break fail rate | Gate test before acid |
| Claims | Adhesion failures traced here | Claim root-cause share | Record discipline |
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: hot caustic cleaners burn skin and eyes badly. Face shield and apron at addition, add chemicals to water, stir-in fully before loading parts.
FAQ
What does a weak cleaner really cost?
Adhesion failures downstream — the cheapest stage on the line causes the most expensive claims.
Which log predicts cleaning failures?
Titration completeness and water-break fail rate at the gate; both move before plating defects do.
Overflow tanks — water vs chemicals trade?
Counter-flow overflow strips oil continuously; the water cost is smaller than one adhesion claim.