Unfortunately, even when all of the foregoing set-up procedures have been used, there may come a time when a problem occurs.

This may also be the result of inheriting an ‘old process’ that had flaws in its original design.

Electroplating-assistance.co.uk can guide you through the DMAIC Method of identifying, quantifying, and solving a problem – including the incorporation of stages to avoid its repetition.  (The “Control” phase).

Many ‘tools’ are readily available to do this, but selection of the correct ones and their correct implementation is paramount.

Be prepared to think “outside the box”.  Very rarely are problems unique.  More usually, similarities with apparently unrelated processes can help us to find the way.

The picture right, shows a phenomenon that can affect any combination of metals (and non-metals) that have been heated!

The ability to measure the problem is essential.  Methods to consider are:

pH meter	many plating processes are very pH sensitive
Conductivity meter	affects throwing power and other factors
Titration	correct concentration of each ion
XRF	useful for: metal concentration; thickness (inc. multi-layer); composition
Hull cell	easy to demonstrate many features of a solution – and assess corrective actions on a small volume of solution

There are many tools for investigating problems.

One of the best is “an embellished 5-Why’s” approach:-

The Cause Map