ARMOR worked with Ford Motor Company to solve a chronic corrosion issue that resulted in savings of more than $125,000 each year.

Before

After

Customer
Ford Motor Company, Van Dyke Plant

Type of Industry
Automotive transmission and transmission components.

Problem
ARMOR and Ford conducted testing to isolate variables and found that the warm parts placed inside the container and competitive VCI bag created a “greenhouse effect” which resulted in moisture in the container and eventually rust on the hubs. The “cost” of these complaints and the de-rusting efforts to resolve them exceeded, on average, $125,000 per year, not including transportation, re-work, administrative costs or cost incurred by the customers in handling and managing returns.

Previous Rust Removal Method
The Ford Van Dyke Plant received numerous customer complaints of corrosion on hubs. During this period, a competitor’s VCI bag was used when parts were shipped.

ARMOR Solution
ARMOR recommended several process changes in the plant including a brief cool down time before closing the bags. In addition, Ford placed large sheets of ARMOR WRAP® 30R paper as interleaving between several layers of hubs. An ARMOR POLY® VCI bag was also used to line the cages. This ARMOR WRAP® and ARMOR POLY® combination proved successful in eliminating the rust.

Results/Savings
In excess of $125,000 per year.