Ceramic Engineering & Science Proceedings MAY-JUNE 1993 Proceedings of the 54th Porcelain Enamel Institute Technical Forum Douglas D. Giese Conference Director September 16-1 7,1992 Nashville, TN Published for The Porcelain Enamel Institute by The American Ceramic Society 735 Ceramic Place Westerville, OH 43081- 613 6 Copyright 0 1993 The American Ceramic Society and The Porcelain Enamel Institute, Inc. ISSN 01964219 Executive Director Editor W. Paul Holbrook John 6. Wachtman Director of Publications Production Assistant Linda S. Lakemacher Lori A. Kozey Committee on Publications: Delbert Day, chair; Richard Hommel; J.T. Adrian Roberts; David W. Johnson, Jr., ex officio; John B. Wachtman, ex officio; David Green, ex officio; W. Paul Holbrook, ex oficio. Editorial and Subscription Offices: 735 Ceramic Place, Westerville, Ohio, 43081- 613 6. Subscription $69 a year; single copies $30 (postage outside U.S. $8 additional). Published bimonthly. Printed in the United States of America. Allow four weeks for address changes. Missing copies will be replaced only if valid claims are received within four months from date of mailing. Replacements will not be allowed if the subscriber fails to notify the Society of a change of address. CESPDK Vol. 14, NO.5 -6, pp. 1-128, 1993 The American Ceramic Society assumes no responsibility for the statements and opinions advanced by the contributors to its publications, or by the speakers at its programs. The opinions expressed are not necessarily those of the Society, its trustees and officers, its staff, or its general membership. Copyright 0 1993, by the American Ceramic Society. Permission to photocopy for personal or internal use beyond the limits of Sections 107 and 108 of the U.S. Copyright Law is granted by the American Ceramic Society, provided that the base fee of US$2.50 per copy, plus US$.50 per page, is paid directly to the Copyright Clearance Center, 27 Congress Street, Salem, MA 10970, USA. The fee code for users of the Transactional Reportin# Service for Ceramic Engineering and Science Proceedings is 01 96-6219 /93 2.50+$.50. This consent does not extend to other kinds of copying, such as copying for general distribution, for advertising or promotional purposes, or for creating new collective works. Requests for special photocopying permission and reprint requests should be addressed to the Director of Publications, The American Ceramic Society, 735 Ceramic Place, Westerville, OH 43081. Each issue of Ceramic Engineering and Science Proceedings includes a collection of technical articles in a general area of interest. These articles are of practical value for the ceramic industries and the general public. The issues are based on the proceedings of a conference. Both American Ceramic Society and non-Society conferences provide these technical articles. Each issue is organized by an editor who selects and edits material from the conference proceedings. The opinions expressed are entirely those of the presentors. There is no other review prior to publication. Foreword Comments by the Technical Forum Chairman It has been a great personal pleasure for me to serve as chairman of this year’s PEI Technical Forum. As you well know, there are a host of individu- als who have worked hard and contributed greatly to the success of this 54th in the long series of meetings, the first of which was held on the campus of The Ohio State University in 1937. Until four years ago, the annual event alternated between Ohio State and the University of Illinois. I want to thank my Vice Chairman, Rusty Rarey, for all of his efforts and hard work. Also, I am most grateful to members of our large and productive committee that developed the program format, decided on the individual topics for papers, and then went out and obtained the authors who prepared and presented the papers. A special thanks goes to all of the speakers and panelists for their time and effort. Also I want to express the appreciation of all of us to the many supplier companies that had booths in the Suppliers’ Mart this year and, as exhibitors, sponsored the enjoyable reception on two evenings of our meeting. The program this year aimed to respond to the interest of the industry. The papers and panel sessions were geared to discuss those subjects currently receiving attention in our plants and in our laboratories today. The results of the two-day session are contained in these proceedings, which will join earlier volumes as useful reference pieces for our industry. Looking ahead, we hope to see you all at the 1993 PEI Technical Forum which will be held, for the first time, in the spring of the year. Nashville will again be the host city; the dates will be May 10-13. Douglas D. Giese, GE Appliances Chairman, 1992 Technical Forum Committee iii 54th Porcelain Enamel Institute Technical Forum ... The Business of Paradigms Discovering the FutureA Video ............................................. Presentation 1 Joel Arthur Barker and Arnold Moss Why Register Your Quality Management System with the IS0 9000 ............................................... Standard? 2 Ronald Buras Optimization of Enamel Properties by Statistical Experimental .................................................. Design 5 Elie E. Saad, EJ. Pawlicki, Derek W. Sproson, and Phillip D. Lunney ........................ Statistical Process Control in the Shop 13 Tony Noltemeyer ......... Statistical Process Control Case Histories4 Panel Session 17 Jeffrey Sellins, David Thomas, and Walter Skovron ........... Progress in Direct-On Enameling on Cleaned-Only Steel 22 Wolfgang Podestti ............ Plant Experiences with Premilled Frit-A Panel Session 34 Jeffrey Sellins, Terry L. Conrad, and Louis Gazo The Development of Alkali-Resistant Powder Porcelain Enamel ................................................ Systems 37 Mitchell Horton .............. Plant Experiences with Powder Porcelain Enameling 45 Walter Skovron and William Schieferstein ................ Outlook on the Availability of Key Raw Materials 48 Peter Morden ........................ Lithium’s Role in Porcelain Enameling 51 Robert Cinq-Mars ...................... Role of Cobalt Oxide in Porcelain Enamel 52 Ann M. Lynch ............ Cobalt Reduction in Ground Coat Glass Compositions. 58 Melvin C. Grimes V . . . . Responding to the Current Cobalt Situation4 Panel Session , , , 61 Holger F. Evele, Anthony Mazzuca, and Melvin C. Grimes .............. Clean-Only Porcelain Enamel Systems-h Overview 64 David E. Savage ..................... The Cleaner's Role in Clean-Only Systems 71 William Wittke Black Specks in Porcelain Enamel: The Role of Forming Compound, .......................... Cleaner, and Steel Surface Condition 72 Donald Fisher, Robert Reid, Holger F. Evele, and Donald Sauder .................. Cost Savings Through Cover Coat Reclamation 87 Marc W. Nagley ............... Current Environmental Issues-4 Highlight Report 88 Jack E. Waggener ..................... Emerging Health and Safety Requirements 89 James J. Carleton ..... Report on the Work of the PEI Furnace Atmosphere Committee 95 Holger F. Evele ......................... Enameling Steels-Focus on Hydrogen 98 C.R. "Rusty" Rarey ........................... Drawing and Stamping Lubricants 107 Jon L. Krussow ............................. Forming Lubricant Technology 109 Jon L. Krussow ................................... Electrophoresis Update 116 Frederik C. Sas and Donald Greenwood .................... 1992 PEI Technical Forum Attendance List 119 vi Ceramic Engineering & Science Proceedings Douglas D. Giese Copyright0 1993 The American Ceramic Society and The Porcelain Enamel Institute, Inc. Ceram. Eng. Sci. Proc. 14[5-6] p. 1 (1993) . . . The Business of Paradigms Discovering the Future-A Video Presentation JOELA RTHURB ARKER Charthouse Learning Corp. Burnsville, MN 55337 ARNOLDM oss Magic Chef, A Division of Maytag Co. Cleveland, TN 37320 Editor's Note The video, "The Business of Paradigms . . . Discovering the Future," featuring Mr. Barker, was presented to the Technical Forum audience. Permission for the use of the video was obtained by PEI from Charthouse Learning Corp. The film's message is directed at managing change. It underlines the essential step of breaking out of established paradigms. Unfreezing established patterns of action and breaking away from the "business-as-usual" approach are emphasized. Mr. Moss utilized the key points in the film and related them to practical, everyday circumstances in a typical appliance manufacturing plant. He pointed out how the message in the film can be applied regularly to aid in solving problems and broadening the approach to challenges faced each day in each person's own company. 1 Ceramic Engineering & Science Proceedings Douglas D. Giese Copyright0 1993 The American Ceramic Society and The Porcelain Enamel Institute, Inc. Ceram. Eng. Sci. Proc. 14[5-6] pp. 2-4 (1993) Why Register Your Quality Management System with the IS0 9000 Standard? RONALDB URAS Ferro Corporation Cleveland, OH 44101 IS0 9000 is described. Benefits gained from the development of a quality management system are identified. Advantages for the company and its custom- ers from registering the system with the IS0 9000 standards are listed IS0 9OOO is a quality management standard. More appropriately stated, it is a management standard. The management of some companies is likely to assign responsibility for IS0 9OOO to the laboratory because of the word quality in the title. Because it is a management standard, that is not where it fits. IS0 9OOO was developed by the International Organization of Standard- ization, located in Geneva, Switzerland. It was not created by the Europeans. It is based on an old U.S. military standard. It was adopted by the Europeans because of the EC 1992 directive. The EC directive states that companies within the European Community shall preferentially purchase raw materials from IS0 9ooo certified suppliers. The standard sets up guidelines for developing management systems taking into account the technical, administrative, and human factors involved in managing an operation. It is used to develop a management system that will ensure your ability to meet your customer requirements. It is currently being applied by the EC in regulated industries such as electronics, toys, and transportation. The standard outlines management's responsibilities relative to developing a system that will ensure that customer requirements are consistently met. Product quality cannot be ensured if management does not lead the operation. Ronald Buras received his B.S. degree fiom Louisiana State UniverSiiy in 1980. Prmently, he is manager of corporate quality at Fen0 Corporation with the reqwmibilily of coorhting IS0 goo0 for his company Previous@,h e was quality and safety manager for Fmo 's Gram Chemical Division 2 IS0 9ooo takes into amunt the elements as outlined in the quality loop. If the elements of the loop are not managed, the loop opens up, creating an opportunity for a system failure. The failure is defined as faiIing to meet customer requirements. The greatest opportunity for system failure is in not defining customer requirements. The next greatest opportunity for failure is in not planning production and not providing the tools and resources necessary to get the job done. The management of Ferro Corporation has committed to certifying every operation within the worldwide organization, including the research and development center, to IS0 9OOO standards. Why register your system to IS0 9OOO? It may be necessary to certify some organizations because the customers are not asking for it and there are little to no exports into the EC. The reasoning behind certification in these situations is to ensure the effective development and implementation of the management system. A system meeting the IS0 9OOO standards is an excellent foundation for a total quality management system. Certification requires that you maintain the system. If the system is not maintained, you can and will lose certification, which sends the customer the signal that you are not committed to meeting their requirements. A letter has been published by a general in the Pentagon stating that IS0 9OOO standards will replace the MIL specs. It may take years, but it has been stated this will happen. Unlike some MIL standards, IS0 9OOO does not specify product requirements or tell you what you must do to meet these requirements. It leaves the establishment of product requirements to you and your customers. The standard does state that once the requirements are established, you will develop a management system that ensures your ability to meet those requirements day in and day out. Dr. Joseph Juran stated that companies that do not meet the IS0 9OOO standards today will not be in business in the not-so-distant future. He stated that these standards are very generic and are the minimum requirements for a management system. One of the benefits of developing the system is the establishment of standardized work practices. A result of standardized work practices is decreased product variability. Another outcome of IS0 9000 implementation is that the process is forced down the supplier chain, resulting in standardized raw material. These elements together will decrease fluctuation in your process, allowing for better, more consistent process control. Everyone benefits from a quality management system. How does the system get developed in an organization that is overworked and already stretched to the limits? The most effective method is to use all 3 resources available. Management is responsible for the system, but manage- ment should not write all of the procedures. The personnel who perform and who use the procedures should be held accountable for writing those proce- dures. By allowing the operators to write the procedures, they take ownership in the system and will accept change. One benefit of standardized work practices is the use of these documents as training tools. When everyone is trained on proper equipment operations, safe work practices naturally result. One operation of 100 employees with an average of 3 lost-time accidents per year has successfully turned its safety program around to zero lost-time accidents over a 3-year period. Decreased product variability also allows for decreased waste generation. As process control improves, product variability decreases, the amount of waste generated decreases, and customer satisfaction increases along with profitability. The process becomes easier to change as customer requirements change. The American Society for Quality Control is an excellent resource for information concerning IS0 9OOO. 4 Ceramic Engineering & Science Proceedings Douglas D. Giese Copyright0 1993 The American Ceramic Society and The Porcelain Enamel Institute, Inc. Ceram. Eng. Sci. Proc. 14[54]p p. 5-12 (1993) Optimization of Enamel Properties by Statistical Experimental Design ELIEE . SAADE, .J. PAWLICKDIE, REKW . SPROSONAN, D PHILLIDP. LUNNEY Miles, Inc. Industrial Chemicals Division Baltimore, MD 21224 Experimentation is the most important tool in the research and development of new and improved products and processes. Mth this in mind, a statistically designed series of experiments was carried out to optimize the gloss in convention- al glazes. In particular, the Taguchi approach to experimentation coupled with a mixture design was used. By selecting pertinent compositional parameters that may affect gloss, experiments were conducted to determine the relative importance of these factors. Statistical anarysis of the resulting data is presented. Introduction TheT aguchi approach' to experimentation has been used extensively in Japan and is quickly gaining acceptance in the United States as being an extremely valuable tool for industrial research and development. This technique is primarily a methodological approach to performing experiments, and allows one to study multiple process variables simultaneously Elie E. Saad a research specialist in porcelain enamel and ceramic coatings, is presenth the manager of research and development at Miles, Inc. Dr. Saad received a BA. degee in physics and mathemat- ics from Cornell and a PhD . in applied physics from The Catholic University of America A member of the American Ceranuc Society and the Materials Research Society, he holds two patents and has published over 20 articles. E.J. Pawlick' received his B.S. &gee from Alfred University and his M.BA &gee from the University of Buffalo. He is m g e ro f technical sewices-ceramiksf or Miles, Inc. Derek LK Sproson received his education at Penn State University. He holdr a B.S. degree in ceramic science and engheering and a Ph.D . in ceramic science from the university. He is manager, technical service and applications development for Miles, Inc. Phillip D. Lunnqt holds both a B.S. and an M.S. degree from Clemson University. He also received his M.S. in chemical engineering from the University of Arkansas. He is mfacnrring specialist for Miles, Inc., with responsibilities for process improvement and customer technical service. 5