IMPLEMENTATION OF COMPLIANT SURFACE COATINGS BOEING DEFENSE AND SPACE GROUP HELICOPTER DIVISION

Transcription

1 MPLEMENTATON OF COMPLANT SURFACE COATNGS BOENG DEFENSE AND SPACE GROUP HELCOPTER DVSON CuaC1?q s -p / The facility wide conversion to low VOC aerospace primers and topcoats for 85% of the surface coatings usage at Helicopters Division will be complete by July 1, The environmental benefit will be a major one, reducing plant wide VOC emissions from surface coating operations by 50%. Beginning in August, 1991, this program was established to respond to State (PADER) agency on VOC (Volatile Organic Compound ) emissions from the six major paint facilities on site. The implementation plan, developed by SHEA, Manufacturing Technology, and Materials Engineering, was divided into three phases. Phase involved the factory conversion to waterbased epoxy primers and high solids epoxy topcoats, which comprised 70% of the coatings usage facility wide. Extensive screening and qualifications testing were necessary to approve these coatings for production use. On December 20,1991, M&P Engineering had completed the testing required to approve these new materials for use on military programs. n addition, Boeing Materials Technology in Renton WA was conducting their own qualifications testing program, and had already tested and approved low VOC primers and topcoats for use at Helicopters Division on commercial hardware. The Phase effort was completed by August 2, 1992 and reduced VOC emissions by 35%. Phase 1 was completed on July 1, 1993 and involved the replacement of all lacquer topcoats for military programs with a high solids chemical agent resistant (CARC) polyurethane that was qualified under Phase testing. Phasing in these new coatings require significant facilities modifications to fulfill unique applications criteria. Also their incorporation into the factory will have to be carefully managed, since they change aircraft configuration or the performance characteristics of the aircraft. Consequently, all downstage details and assemblies painted with the new ccatings must be identified for installation on specific helicopters. This requires much negotiation with customers to accept the change, and thousands of labor hours required to orchestrate their implementation into production. This effort impacts 15% of the coatings usage facility wide, further reducing VOC emissions by an additional 15%. i Phase 111 involves the qualification and implementation of alternatives for the remaining coatings, mainly special performance coatings and adhesive primers. These coatings comprimise the remaining 15% of the surface coatings usage at Helicopters. Their low VOC substitutes will be the most difficult to qualify due to the lack of currently available candidates. The Boeing Company, however, has been conducting - an intensive effort to find suitable reulacements. An elaborate interdivisional technology -- exchange network has been set up to disseminate information and report program status. HD targeted a 100% conversion to low VOC coatings by the first quarter of 1995 based on the implementation schedules from within the Boeing Company.

2 '1 i P h c, Figure 17 v. L. Mangold, Jr. Page 24

3 . Manufacturing Technology Objective The elimination or the reduction of the use, release and disposal of hazardous chemicals and materials in the workplace Scope 0 Chlorinated Solvent Replacement 0 Volatile Organic Compound Reduction / Elimination 0 Non-Chromated Processes 0 Chlorofluorocarbon Elimination 0 Coolant Recovery 0 Cyanide / Cadmium Elimination 0 Waste Minimization

4 fig 0 70% implementation by August 2, 1992 complete 0 Conversion to polyurethane topcoats by mid 1993 p,w &$ e"",.- ; 1 " kvr" 0 Compliant substitutes for remaining non-compliant materials under investigation. Man Tech and M&S presently coordinating test matrix with Boeing Materials Technology 0 Full conversion to compliant coatings by January 1995

5 SURFACE COATNG USAGE PERCENTAGES BASED ON VOLUME mplement by 81 > substi itutes 11.7% 2.7% BASEDON 1991 USAGE %

6 VOC EMSSONS FROM PANT BOOTHS 1990 USAGE DATA 8Q'ooo 0-1 NO ALTERNATVES t Source: 1990 PEDS Report PANT BOOTH

7 i :J BR 127 HGH VOC COATNGS WTH NO AVALABLE ALTERNATVES vcr c 0 y-(l; SCHUTZ 12.1% :OATNGS) 12.3% BMS 10 - BASED ON USAGE DATA

8 Surface Coatings Environmental Benefits 0 35% reduction in VOC emissions by August 2, Additional 15% reduction in VOC emissions by June 1993

9 L Low VOC Milifary Primers and Topcoats Approach: Test specimen preparation Perform qualification testing -- substrate compatibility -- topcoat compatibility -- crack detection -- fluid resistance -- reactivation -- crevice corrosion Production implementation study ndustry survey and interdivisional technology exchange Secure specification coverage Production implementation

10 0 Review background and status of program 0 dentify and resolve major issues: -- Customer approval and contract modifications -- Configuration control -- Production schedule integration -- Program cost impact -- Facilities planning -- Final aircraft touch up 0 Assign responsibilities for these issues to one focal from each affected functional organization 0 Commit identified focals to completion dates for each action assigned 31JF3241mvl 0 Discuss future plans for a timely and coordinated implementation

11 , '. u mplementation will be phased, can be described in 3 steps: Timeframe % of 1990 VOG 1. mplement currently approved by August % compliant alternative coatings -- primers -- epoxy topcoats 2. mplement polyurethane topcoats upon Army 10% as substitute for lacquer acceptance 3. Obtain PADER exceptions for non-compliants without % alternatives -- continue to pursue qualification of viable substitutes (BR 27)

12 Factory mpact 1. Approved Compliant Alternatives (except polyurethane) -- Most coatings will have no impact -- Primers are undergoing factory trials to finalize processes and special requirements % of 1990 voc 2. Polyurethane Topcoats -_ Affects painting of detail parts, sections and final aircraft details in rotor system * 3-B3 50 details -_ Capacity: n general, no constraints Longer flowtime will require 3rd shift in final paint full camouflage -- 7 mix of D and Non-Compliants: Continue to use until compliant alternatives are -S Emission controls may be required if we cannot get exceptions

13 Major ssues and Concerns: 1. BMS 70-1 Water Reducible Primer 0 Select method to apply BMS primer that increases pot life 0 nstall required equipment for BMS primer application 0 Commit to production implementation of BMS primer 0 nvestigate restrictions for using a refrigeration device in the paint shop to chill primer 3GJF617hrM

14 ~ Compliant Production mplementation Major hues and Concerns: 11. ML-P Water Reducible Primer 0 Complete production trials in the following shops: > Resolve dry to overcoat issue Schedule production phase-in and material requirements for ML-P in all shops 0 Liaison application of ML-P primer as required until planning is changed. 0 Report budget status and expected timeframe of BCS mass planning change 0 Resolve compatibility issue with Army concerning polyurethane over zinc chromate 0 Determine vendor usage of zinc chromate 37JF6171mvi 0 Notify appropriate vendors of primer change and select a suitable option, if required

15 j Production mplementation Major ssues and Concerns: 111. ML-C-22750E Epoxy Topcoat 0 Perform qualification tests to allow accelerated drying per ML-C-22750E

16 Major ssues and Concerns: V. ML-C Carc Polyurethane 0 Revise PS 362 and finish and application documents 0 Develop schedule to phase-in polyurethane paints for final aircraft paint #M Develop plan and schedule for poly facilitization that reflects mplementation phase-in schedule from Change Board 0 Release EAMR for the polyurethane paint required for affected aircraft 0 Resolve all rework issues that are not feasible or not approved by customer and report options 0 Liaison application of poly paint as required to cover shop use before plannlng and engineering drawing changes are finalized 0 dentify stripping requirements and cost impact 0 Methods analysis for affected paint shops

17 Production mplementation Major lssues and Concerns: V. facilities / Equipment 0 Modify all required HVLP guns with mod kits for high solids paints

18 0 0 Polyurethane is the only "compliant" alternative for lacquer topcoat. implementation will generate additional recurringhon-recurring costs Recurring (per NC) hrs (D) 200+ hrs (414) Non- Recurring $200-$1 M capital hrs document changes 0 Will require Class ECP from Army. Contract modification for RAF/ other international contracts -- current and future. 0 Method of transition is not definitized: -- Can we avoid part number changes? -- We must get poly details in a poly airframe * No mix of poly/lacquer allowed in the aircraft exterior

19 Method of Conversion Determine a logical changeover point based on existing inventories/flowtime and ECP lead time ~ Establish method of handling configuration control -- Part number change may result from Class ECP Pick initial airplane parts to ensure 100% incorporation Purge and repaint residual inventory

20 MPROVED COATNGWPOLYURETHANE PANT PRR NUMBER (BACKGROUND) PRR WAS NTATED TO CONTROL THE CHANGEOVER AND NCORPORATON OF POLYURETHANE PANT FOR EXlSTlNG CONTRACTS BEGNNNG WTH A/C PROPOSED SOLUTON: 0 REPLACE ZNC CHROMATE PRMERS WTH EPOXY PRMERS 0 REPLACE LAQUER TOP COATS WTH POLYURETHANE TOP COATS 0 COORDNATE CHANGES WTH CUSTOMERS L

21 8 MPROVED COATNGWPOLYURETHANE PANT PRR NUMBER COST STATUS: 1. Develop with customers a "Benefits Analysis" to recoup some of the cost. A. CH47D & MH47E - Still to be negotiated for some recoupment. B. RAF: Costs associated with the deletion of the camouflage paint scheme were traded for the costs of the Polyurethane Paint changeover. C. Greece: None expected. D : Proforma pricing to include delta costs. 2. Reassess overall approach and review estimates in order to minimize total company cost. A. All Customers conceded to allow "Mix and Match" of interior parts, allowing for less costly implementation. B. Functionals streamlined approaches and reduced estimates: WAS: May $5.37 Mil. NOW: Aug $3.73 Mil. CAGENDAl

22 1 MPROVED COATNGWPOLYURETHANE PANT A/C # M3439 ENGNEERNG 1 - (UPGRADES) - PLANNNG RWK / REPANT DETAL FAB EXT. PARTS L-7 DEL

23 1. 0 Total Surface Coatings Affected Substitutes Approved Coatings Without Substitutes No Substitutes Required 2 glf -< -+'d / /',/" J 0 Low VOC Surface Coatings mplemented 3K.' (replaces 55 non-compliant coatings) W 74 / -... ~ Revised 311 0/93

24 MCC# 58H HZ HZ HZ HZ HZ HZ HZ HZ HZ HZ HZ Z HZ HZ HZ HZ HZ HZ HZ HZ HZ HZ HZ HZ HZ HZ HZ H H HZ HZ H HZ H HZ HZ HZ SURFACE COATNGS WTHOUT ALTERNATVES COATNG DESCRPTON TT32/110 Acrylic Roundal Blue No. 110 (BS381C) 'T-L-32 Lacquer Lt. Blue ML-L Lacquer Gm. No h4l-l Lacquer Gm. No Coating Primer Base Protective Coating M Coat D Protective Coating M Coat A Mil-C Antistatic Coating Alkaline Coating Yellow Removable Aztec 649 Coating 306N BAC M Chip Resistant Coating # Conductive Coating Persian Orange Paint G 3010 Mil-L-8937 BAC 5811 Type 1 Dry Film Lubricant Mil-L-23398A Lubribond A DMV - 13 Vinyl Mixing Base PT404A Stencil Paint Black 8-B-6 Magna 50C3 Conductive Coating RTV 1200 Red Primer Mil-C-8514 Wash Primer BMS Type 2 Fuel Tank Primer Vydax 550 Coating Agent EC 776 Clear Adhesive EC1660 Adhesive Bonding Primer BMS 5-63 B4 DAPCO #1-100 Primer EC 776 Clear Adhesive BMS Ty Enamel BAC 702 BMS Ty Enamel 707 Gloss BMS Ty Enamel 7025 Gray Gloss BR127 Adhesive Bonding Primer BMS Ty 2 Grade B Primer BMS Ty 2 Primer BMS Ty 1 Antistatic Coating BMS Ty 3 Antistatic Coating ALB 144 Gray Fire Resistant ML-C C11 Fire Resistant 10P2-4 Cat Hi Build Base Epoxy EC 1103 Protective Coating Tereco 155 Abrasion Resistant % ---- w r c ' 3 2 =- -0 <* \ 3 +