Texas Trouble Shooters hosted by EJIW
Peter Macler presents holistic approach to scrap reduction
30 minute foundry tour followed by the TTS
Lunch at 11:30
Cost of $25 – Please Purchase Tickets Online in advance so that we can get an accurate head count.
- Appearance of the foundry buildings and grounds.
- Interior housekeeping and organization.
- Interviews of key Management Personnel, Production Supervisors, and Quality Control Personnel.
- Review of the past 12 months’ causes and percentages of Scrap or Rework.
- Inspection the Quality Control Facilities, Testing Equipment, and Visible Records for tracking Key Quality Indicators.
- Review of Production Travelers/Routers to determine whether key instructions, diagrams, and photographs are included.
- Review of Shop Floor Records.
- Review of Equipment Calibration and Testing Programs.
- Starting with the receipt of raw materials, are all materials inspected and qualified prior to being introduced into the processes (Isolation)?
- Review the quality/state of maintenance of all equipment and processes.
- Review of work practices that impact quality.
- Observe workers and supervisors performing their roles.
- Observe on-the-floor quality control activities including sampling, and interaction with workers and supervisors when quality issues are discovered.
- Observe how scrap is reviewed with supervisors and workers. Are specific assignments made to individuals and are they tracked until completed?
- Special attention will be given to:
- Pattern and Core box Design, and gating and risering practices.
- Melting charging areas, and melting, tapping, and pouring practices.
- Sand handling, storage, reclamation/recycling, and its preparation for cores and molds
- Sand Mixing and Mulling – Sand Preparation:
- For greensand – including sieve analysis, active clay, compactability, tramp materials, L.O.I. green compressive strength and moisture.
- For Chemically bonded sand – percentage of binder parts and catalyst/activator, sieve analysis, L.O.I., tensile/traverse strength, acid demand value, tramp materials, moisture, and scratch hardness. Frequency of calibration.
- Coremaking practices, finishing, refractory washing, drying, assembly, storage, and handling.
- Molding practices, aeration, screening, moisture, compactability monitoring, mold hardness for greensand. Calibration of binder and catalyst pumps and sand throughput. Use of riser sleeves, filters, chills, and ram-up cores. Poured mold movement and in-the-mold cooling.
- Shakeout, casting separation, sand lump breaking, screening, cooling, and tramp metal separation.
- Reclamation/Recycling of sand.
- Cutoff/Knockoff/Arc cutting
- Riser and gating removal
- Shot blasting
- Heat Treatment
- Finishing Operations: Welding, Heavy grinding, light grinding, trim presses, robotics
- Inspections and Quality Control.
- Quality meetings and scrap review.
October 25, 2019
10:00 am - 1:00 pm