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

2. 2 Overview 4 Integrated Process/Environmental Planning/Design 4 Water and Chemical Recovery and Reuse 4 Software Tools for Improved Decisionmaking and Implementation 4 Life Cycle Information Management 4 Life Cycle Project Improvement 4 Supply Chain Impacts 4 Integrated Process/Environmental Planning/Design 4 Water and Chemical Recovery and Reuse 4 Software Tools for Improved Decisionmaking and Implementation 4 Life Cycle Information Management 4 Life Cycle Project Improvement 4 Supply Chain Impacts

3. 3 PROCESS/ENVIRONMENTAL PROJECTS

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

5. 5 Project Value is Maximized Through Systematic Planning and Implementation 4 Plan for adequate and flexible systems that meet current needs & can be easily modified to meet anticipated contingent/future scenarios 4 Design efficient systems that maximize product quality and yield and minimize waste 4 Implement useful information systems and documentation 4 Meet/exceed goals 4 Avoid constraints 4 Plan for adequate and flexible systems that meet current needs & can be easily modified to meet anticipated contingent/future scenarios 4 Design efficient systems that maximize product quality and yield and minimize waste 4 Implement useful information systems and documentation 4 Meet/exceed goals 4 Avoid constraints

6. 6 WATER AND CHEMICAL RECOVERY AND REUSE

7. 7 Water and Chemical Recovery and Reuse Drivers 4 Reduce wastes 4 Reduce solution contaminants and constituent variations -- improve quality and performance of process solutions and rinse waters 4 Reduce chemical and water use Constraints 4 Buildup of undesirable contaminants 4 Incremental systems that will not be properly operated and maintained Drivers 4 Reduce wastes 4 Reduce solution contaminants and constituent variations -- improve quality and performance of process solutions and rinse waters 4 Reduce chemical and water use Constraints 4 Buildup of undesirable contaminants 4 Incremental systems that will not be properly operated and maintained

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

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

10. 10 A Balance of Integrated Pollution Prevention and Pollution Control Provides Lowest Life Cycle Cost 00.250.50.751 All pollution control All pollution Prevention Increasing costs Increasing pollution prevention

11. 11 SOFTWARE TOOLS FOR PROCESS/ENVIRONMENTAL IMPROVEMENT

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

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

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

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

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

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

18. 18 Process Model Data Can be Exported to Tankline Spreadsheets

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

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

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

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

23. 23 LIFE CYCLE INFORMATION MANAGEMENT

24. 24 Planning 1 year Design 18 months2 years Facility Management 20 years Construction Planning Provides Awareness of Data Generation Over Project Life Cycle DATA

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

26. 26 Early Data Input Maximizes Data Utility Planning

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

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

29. 29 Benefits of State of the Art Project Data Systems 4 Data is more accessible and reliable 4 Accurate, reusable information for project lifecycle 4 Improve project understanding and communications 4 Reduces cost and accelerates project delivery time 4 Lower risk for changes, conflicts, errors and omissions 4 Increased staff productivity due to easier access & availability of data 4 Improved record-keeping and cross-referencing 4 Data is more accessible and reliable 4 Accurate, reusable information for project lifecycle 4 Improve project understanding and communications 4 Reduces cost and accelerates project delivery time 4 Lower risk for changes, conflicts, errors and omissions 4 Increased staff productivity due to easier access & availability of data 4 Improved record-keeping and cross-referencing

30. 30 Integrated Process Planning and Information Tools Produces Excellent Benefits 4 Establish requirements, goals, constraints 4 Understand impacts of production ranges on process systems and support systems 4 Plan efficient life cycle information management systems 4 Maximize opportunity to incorporate productive, efficient, lean, profitable systems 4 Initiate effective life cycle implementation and mechanisms for continuous improvement 4 Improve project delivery approach, information sharing, efficiency, ability to control project, and ability to integrate beneficial technique and technology 4 Establish requirements, goals, constraints 4 Understand impacts of production ranges on process systems and support systems 4 Plan efficient life cycle information management systems 4 Maximize opportunity to incorporate productive, efficient, lean, profitable systems 4 Initiate effective life cycle implementation and mechanisms for continuous improvement 4 Improve project delivery approach, information sharing, efficiency, ability to control project, and ability to integrate beneficial technique and technology

31. 31 Supply Chain Considerations Motivation 4 Respond to Requirements 4 Opportunity for Improvement Impacts 4 Efficiency 4 Quality 4 Profitability Motivation 4 Respond to Requirements 4 Opportunity for Improvement Impacts 4 Efficiency 4 Quality 4 Profitability