Simple Solutions That Work! Issue 9

Repurposing a Tight Flask Mold Line Challenge: Using a de-commissioned 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. Results: By working with the customer to meet the available space criteria, existing sand system and melt requirements, an efficient mold line solution was designed that incorporated the existing mold machine and decommissioned mold handling units. This particular project would not have been fiscally possible if we weren’t able to save more than one million dollars when compared to a new tight flask mold line. This opportunity is unusual as it’s not every day that existing large tight flask mold handling systems are available. Recognizing the possibility and partnering with the right solution provider delivered a remarkable and cost-effective system that will be in production for decades to come. These are just two examples how re-purposing existing equipment can be put to work in any foundry application. Foundry Managers that are facing the same project dilemmas discussed in the introduction (budget constraints or lead time challenges) should consider partnering with suppliers that look for solutions first and not always focused solely on new equipment sales. Contact: JERRY SENK [email protected] 46 Overall Machine Status Cooling Selection Auto-Mode Status Automatic Mold