Simple Solutions That Work! Issue 17

19 BACK TO BASICS Continued on next page necessary provided a new machine with substantially reduced costs and faster lead time. Results: In this case the repurposed core machine was delivered at a cost savings of over 50% when compared to an equivalent new machine and the delivery time was reduced by 8 weeks. The production goals met the objectives for cycle times and core quality. The catalyst gassing system was modified from amine gassing to CO2 gassing, thus eliminating the need for additional amine delivery systems and air pollution control such as a scrubber. REPURPOSING A TIGHT FLASK MOLD LINE Challenge: Using a decommissioned mold handling line as the basic foundation for a complete newly designed tight flask index mold line. Solution: Working with the customer to update an existing low production mold line into a state-of-art highly productive molding system, the customer was able to identify an available mold handling system that had been decommissioned. It was necessary to create an appropriate layout that utilized as much of the decommissioned system as possible, re-used their existing four post mold machine and handling and to add an automatic weight transfer system. New handling units were added that created a new mold line able to support the large tight flask production needs and address mold transfer, support, and core setting requirements. The customer desired a high production solution that offered innovative production interfacing and diagnostic display. The goal was to create a system that was easy for un-trained operators to learn and operate efficiently and safely. By adding today’s controls and automation solutions any of the foundry’s operators can quickly learn to operate the entire mold line and production data is exported to the companies distributed control system. BEFORE AFTER