Expired 2019 TTS Training

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.

TTS Outline

1. Appearance of the foundry buildings and grounds.
2. Interior housekeeping and organization.
3. Interviews of key Management Personnel, Production Supervisors, and Quality Control Personnel.
4. Review of the past 12 months’ causes and percentages of Scrap or Rework.
5. Inspection the Quality Control Facilities, Testing Equipment, and Visible Records for tracking Key Quality Indicators.
6. Review of Production Travelers/Routers to determine whether key instructions, diagrams, and photographs are included.
7. Review of Shop Floor Records.
8. Review of Equipment Calibration and Testing Programs.
9. Starting with the receipt of raw materials, are all materials inspected and qualified prior to being introduced into the processes (Isolation)?
10. Review the quality/state of maintenance of all equipment and processes.
11. Review of work practices that impact quality.
12. Observe workers and supervisors performing their roles.
13. Observe on-the-floor quality control activities including sampling, and interaction with workers and supervisors when quality issues are discovered.
14. Observe how scrap is reviewed with supervisors and workers.  Are specific assignments made to individuals and are they tracked until completed?
15. 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.
    • Shipping
    • Other