Simple Solutions That Work! Issue 13

6 costs, productivity, labor rates, materials, utilities, preventative maintenance, and competency of the core room operators. When analyzing core machine requirements, you must consider the entirety of the core production, the number of cores per tool (or core box), the number of cores per year, and operating hours. With this basic data in hand, an analysis of production times and potential improvements can be made that will help to identify the correct size (blow capacity and box size) to meet the foundry’s needs for today and the future. 4. RECORD KEEPING What’s critical and often forgotten, is careful recordkeeping of the sand, resin and machinery settings when a quality core is produced. The long list of variables that go into making a quality core is amazingly complex, and easily forgotten. Ensure the attention to record keeping is as detailed as the attention to all other processes. Keeping track of the system parameters is an excellent practice that should begin with the first trials of any core box. The tendency to change several inputs at one good core production. Another way to help eliminate core defects between different core products (or SKU’s) and different core boxes is to utilize the core machine’s Programmable Logic Controllers (PLC’s) with recipe functionality. This is a relatively easy add-on feature for modern core machines that use PLC and Human Machine Interface (HMI) to control the operation of the core machine. Since many foundries rely on older relay-based core machines, this can be a costly add- on. Using recipe functions is a great alternative to operator set- up and adjustments. The HMI and PLC can control the core machine automatically without the operator having to effect manual adjustments. Once this matrix is complete and proven operational, the core machine operator only has to enter the SKU information into the HMI and the machine will take over from there. A more advanced step can use RFID chips mounted on the tooling with a machine mounted reader, then the recipe adjustments are made automatically; without chance for operator error. By using accurately recorded process data along with current instrument and controls technology, the core room operators can deliver higher quality cores with less likelihood of defects. 5. CLEANLINESS AND OVERALL MAINTENANCE The most often overlooked process variable is ensuring cleanliness of the tool and the core machine before and during production. Cleaning the vents and parting lines, blowing off the cope or gas sealing areas is an important step in process. Pattern spray applications can also be critical, as foundries have become accustomed to using compressed air blow-off to aid in this step. But with the implementation of the “silica rule”, this may create added challenges to any core room operation. time (blow, gas, exhaust, etc) should be resisted. The best methodology is to change one parameter at a time. Document and record each setting until you have picked a consistent set of parameters for