In-House Coating versus Job Coating Service - PLATIT
In-House Coating versus Job Coating Service - PLATIT
In-House Coating versus Job Coating Service - PLATIT
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<strong>In</strong>-<strong>House</strong> <strong>Coating</strong> <strong>versus</strong><br />
<strong>Job</strong> <strong>Coating</strong> <strong>Service</strong><br />
I Fve Axis Ma(h ninS<br />
r Cr nding<br />
I ToolCoal ig<br />
I E0l\4 Slrategies<br />
I CAD/CAf/]<br />
-l lllltr<br />
rJ\l I I il5<br />
Advanced C oatin g Systems<br />
swrsslYouALrTY<br />
PLATTI AG<br />
Moosstrasse 68<br />
CH - 2540 G renchen<br />
Te[: ++41 (0)32 654 26 00<br />
Fax: ++41(0)32 654 26 83<br />
E-Mait: info@pLatit.com<br />
www.ptatit.com<br />
O Cart HanserVerlag, München.2005. Att fights including reprinting. photographic reproduchon and<br />
rlanslahon reserved by the pubLishers.
<strong>In</strong>-<strong>House</strong> <strong>Coating</strong><br />
<strong>versus</strong> <strong>Job</strong> <strong>Coating</strong> <strong>Service</strong><br />
I Tibor Cse[Le<br />
SmalL ond medium-sized high-tech-componies who integrate<br />
coating in their own production benefit from many advantages<br />
such as higher product quality, more autonomy and reduced<br />
cosß which result in higher profiß. >AIL leading tooL producers<br />
con handle cutting mateial and geometty. The ones, who use<br />
the best coating technoLogies, wilL have the biggest shares on<br />
the high-tech morket< [2]. That is why the way of masscoating<br />
cannot be the way to future for high-tech SMEs.<br />
The policy of cheap mass-coating cannot I Has the job coater been making an<br />
be the future for srnatt and medium-sized extra profit for himself, from my<br />
high-tech-companies (Sit4 E). Those who pocket?<br />
integrate coating in their own produc- I If prices fatt this tow, does it stj[[<br />
tion benefit from many advantages such make sense to have an own coating<br />
as higher product quality, more autonomy<br />
and reduced costs. Sf4Es who ptan<br />
centre?<br />
on integrating coating in their mechanic The answer for the first question is obvi-<br />
manufacturing can count on an immedious. To answer the second question, the<br />
ate advantage. <strong>Job</strong> coaters wjt[ visit mechanical engineer needs to find an-<br />
them soon and lower their prices (usuatswers to more questjons. This artjcte tries<br />
ly around 30 per cent) >exclusivety< for to summarize these questions and an-<br />
them. After the visit, two questions will swers in the perspective of smatt- and<br />
come up immediatety:<br />
medium-sized enterprises (S!1Es).<br />
Fig. 1. <strong>In</strong>tegration of coating into the mechanicaI production p,o-<br />
cess of a service oriented company,<br />
swlss euAL ry pRoDUcr on jl aucusr zoos<br />
<strong>Job</strong> 6aiing in l6rge unitg<br />
Can SMES reatly coat wiihout prior experiences<br />
and without a Ph.D. physicist? The<br />
answer is: Yes. Numerous examples of<br />
smat[ and medium-sized toot-manufacturers,<br />
regrinders. mold and die makers, injection<br />
motders, machine producers and<br />
even of tool t.aders show thaL integraLion<br />
of coaLing in Lhe mechanical production is<br />
state of the art (Fig. 1) [6 and 7].<br />
SMEs can easily coat<br />
without prior experiences<br />
Can Si\'.1Es produce quality-coatings with<br />
constant composition, [ayer thickness, and<br />
cotor? <strong>In</strong> the own coating-shop the tooß<br />
are not coated together with foreign toots<br />
or even with totatty different parts jn the<br />
same batch. 50 the layer thjckness, composifion<br />
and even the choice of coating<br />
does not depend on what are currentty running<br />
in thejob coating centre (Fig. 2). For<br />
S14Es onty compad and flexible coating<br />
units can be considered. These have to be<br />
abte to produce every coating that is avail<br />
abte on the market. At the same time productivity<br />
ofthjs compact machine has to be<br />
high, so that up to six different coatings<br />
can be deposited in a day (Fig.3).sMEs can<br />
also deposit special coatings according to<br />
special apptications or even generate own<br />
brands wjth the hetp of the own in-house<br />
coating, as shown in Fig.4 and 5.<br />
Do SMEs have an answer shoutd the big<br />
job coaters come to the market with<br />
newty developed coatings? The answer:<br />
! The S[4E shou[d be very careful when<br />
buying a coaLing sysrem from machine<br />
TiAICN+DLC: GRADVIC!<br />
Fig. 2. Main difference between treatment of tools by job coaters<br />
and in-house €oaters,
PFPrcdLdMIyftdot<br />
Fig. 3. Comparing<br />
productivity of<br />
coating units with<br />
different PVD technoloqies.<br />
Source:<br />
Pretat<br />
Fig. 6. Mitting of<br />
gears with conven-<br />
tional and nanocomposite<br />
coatings,<br />
shorter delivery time than job coaters<br />
normally offer (2 to 14 days)? With best<br />
logistics and express-service job coaters<br />
cannot coat most urgent parts in hours.<br />
Delivery time for coatings<br />
can be reduced to 24 hours<br />
The typicat time of detivery is a week<br />
(job coating for SMEs) which can be reduced<br />
to 24 hours (in-house coating).<br />
Through the jntroductjon of a minimum<br />
order quantity job coaters show more<br />
and more that they are not actuatly<br />
interested in sma[[ customers. The total<br />
of needed toots has to be two to three<br />
times higher than a weeks suppty<br />
because of job coaters. Therefore inhouse<br />
coating can reduce storage costs<br />
significantly. There is a risk for damages<br />
or mix-ups at packing and unpacking to<br />
and from the job coater to occur. With<br />
in-house coating these activities are unnecessary.<br />
Experience shows that personnel<br />
costs of in-house coating do not<br />
exceed costs those for logistics of job<br />
c0aters.<br />
But what about the foltowing question:<br />
Does the company have probtems with<br />
manufacturers which run job coating<br />
centres in the same country. He has to MANUFACTURER<br />
, cobalt-leaching at recoated toots? With<br />
in-house coating, the optimaI productjon<br />
ask for a contract assuring that he atso <strong>PLATIT</strong> AG<br />
', cycl.e for reground toots can be mainobtains<br />
atl new devetopments of the<br />
manufacturers immediately. otherwise<br />
the machine manufacturer wou[d<br />
CH-2540 Grenchen<br />
Phone +47/32/6 54 26 00<br />
Fax +4r/32/6 54 26 83<br />
::..<br />
:.r:<br />
,<br />
tained: Decoat - Regrind - Recoat. Therefore<br />
the dangerof cobatt-teaching by decoating<br />
is being etiminated. Usuatty at<br />
naturatty prefer his own job coating<br />
centres.<br />
www.ptatit.com<br />
"'<br />
job coating, regrinding precedes decoating<br />
and recoating.<br />
I The compact system which SiVEs buy<br />
has to compty with the latest tech- technologies, with Larger companies hav- And do SMEs want to determine the preniques<br />
r'n coatjng technotogy. ing to catch up later. Do SMEs need a treatment for active surfaces and E<br />
: An investment in current technotogy<br />
is better than buying conventional<br />
systems: The potential for devetopment<br />
of standard and dominant AtTiN-<br />
600<br />
tayers is limited physicalty [4 and 7].<br />
500 Source: Schl€nk€r,tool g nder, Böblhgen<br />
These borders can be crossed with<br />
nanocomposite layers [1, 3 and 7]. These<br />
400<br />
are already being produced by LARCtechnotogy<br />
by Si\4Es in rnore than 35<br />
300<br />
I<br />
compact-systems worldwide.<br />
Practice shows that leading job coaters<br />
200<br />
had to come up with new coatings be-<br />
100<br />
cause of the SMEs' new coatings (as<br />
demonstrated jn Fig. 6).<br />
0<br />
calldus -AlTiN lgneus -<br />
This fact is not a new phenomenon in<br />
nenocomposite<br />
mechanicaI engineering. <strong>In</strong>novative SMEs Fig. 4. Creation of new nanocomposite-coatings and private brands by SME with the help of<br />
develop and manufacture new products or their in-house coating - Mitl.ing of high al.toyed steel X4OCrMoV5. Source: Unimerco<br />
iwr5s erra-rrw oFoDLcrror !<br />
nrr,rs, zoo"
cutting edges on their own? Wett, since<br />
job coaters cannot know the surface<br />
consistency of various objects, usuatly<br />
they micro-btast a[[ toots to avoid bad<br />
coating adhesion. This can negative[y<br />
affect the functional efficiency of finishing<br />
precision toots, which need sharp<br />
cutting edges. The performance of toots<br />
often depends on the speciat configuration<br />
of cuttjng edges, die geometries or<br />
contact surfaces, and the [ike. 0f course,<br />
Si\4Es do not like to give away their sma[[<br />
and big secrets. But their competitors<br />
often make audits at the job coaters. At<br />
in-house coating, the SiVEs can take care<br />
of their own toots and surety about their<br />
optimaI pretreatment to 100 per cent.<br />
Fig. 7. Ftexible usage of LARC compact-systems with rotating cathodes for coating special<br />
substrates with highest requirements and performance.<br />
<strong>Job</strong> coaters sti[[ have profits<br />
in spite of price reductions<br />
send the parts for coating onty when<br />
coating is absotutely necessary. For that<br />
they do not rnake much money. <strong>In</strong>-house<br />
<strong>In</strong> spite of massive price reductions, job coatjng automaticatty generates setf-<br />
coaters sti[ have good profits. Through profit, new parts to coal and therefore<br />
increased competition, job coaters lower<br />
prices. There are job coaters who openty<br />
business volume (Fig. 1).<br />
say that they onty offer basic coatings, >A[[ leading tool producers can hand[e cut-<br />
but for a mjnimal price. This means comting materiaI and geometry. The ones, who<br />
petition for mass-coaters, but not for use the best coating technotogies, witl<br />
Sf4Es who have to achieve outstanding have the biggest shares on the high-tech<br />
tool performance (Fig. 7). Because of the<br />
disadvantages of job coating, SMEs often<br />
market< [2]. That is why the way of masscoating<br />
cannot be the way to future for<br />
o lnhq ih€ slE orrh. A3ao,<br />
arrbur, Broughlü, Nonh walos, uK,<br />
Mat.: CFC/AI .atbm ibrc<br />
T6lr:solldcalbrß ddlb - rF1{}12 hh<br />
N.nocompsfi. C7 coar€d by unrmerco, lK<br />
Fig. 5, Creation of new nanocomposite-coatings and private brands by SME with the hetp of their<br />
in-house coating - Drilting of sandwi.h materiat CFC/AL<br />
sw rs oJA-r,y DRoDLcrror.r<br />
@<br />
oi,c,-,s,<br />
:oo.<br />
Micro punching<br />
widr GRADVIC@<br />
ctiAtcN+DLc)<br />
HSc{eamins wlth nACCP<br />
lnjectjon mouldins TicrN<br />
high-tech small and medium-size enterprises.<br />
If the future oriented 5ME-owner or<br />
its Chief executive officer answers most of<br />
these questions with )yes