Coating Furnaces & the Innovative Walbar Peabody ERP System

Walbar Peabody has nine furnaces, four coating and five vacuum, with different temperature ranges, most of them reaching up to 2300 degrees. Our operations team handles the coating process, which includes the internal pack and above-the-pack (ATP). For the internal pack, we submerge parts inside the material, which produces a coating on the parts. During ATP, we add coating material to the bell and place the parts on a rack inside the bell. Then the heated coating material produces a vapor that coats the parts. We also braze, solution, and age parts in our vacuum furnaces.

It’s estimated that we work on more than 100,000 parts per year, ranging widely in types and manufacturers! Keep reading for more insight on this intriguing procedure.

Coating Furnace Monitoring Process

Every coating and vacuum furnace has its own computer and encrypted data, which we can control remotely in an emergency. If we have an issue (e.g., a network crash), the computers take over and continue the furnace processes. These processes are coded in the encrypted data, meaning people can’t simply go in and change crucial settings.

So, who oversees the furnaces day to day? There are four furnace operators, one working per shift. We also have one fully cross-trained individual who occasionally supports us as an operator. 

The furnaces also require ERP (enterprise resource planning) software. We’ve used the Citect system for about 15+ years to monitor the furnaces and perform regular updates. Citect must send someone to conduct the updates since they own the software.

Additionally, we have created standard operating procedures (SOPs) to prevent single-point failure. After all, furnaces are very complex systems, and it can be dangerous for someone who doesn’t understand them to try to work on them. Walbar Peabody’s Operations Supervisor, John Minchello, is the primary manager of the coating furnaces, and we have two backup people who can repair them. Of course, we have also developed processes, procedures, and manuals for each aspect of this vital equipment and process. 

Our Approach to Troubleshooting & Process Improvement

With such complex equipment, it’s expected that issues will occasionally arise. Fortunately, our team loves troubleshooting the coating furnaces. We often find that the problem relates to the motors, specifically that a leak has developed. This is when leak detection comes in, and we can usually find it (if we can’t, it indicates a more extensive issue). 

These furnaces are long-standing equipment, so we’ve become adept at troubleshooting and repairing them to ensure they last. Our operations team loves programming and collaborating with engineering to evaluate our processes. Sometimes, when processes have been in place for decades, we realize we can streamline them to increase efficiency. This is the most efficient way we review our current equipment and processes, validate new ones, and modify them as applicable.

The same goes for our tools. About 15 years ago, Walbar Peabody used to buy and dispose of tools once they broke down. John then introduced the idea of repairing our own equipment, which has saved us significant money by increasing its longevity and helped keep us operational. Now, we only buy new tools when something is no longer repairable.