Journal: Frontiers in Manufacturing Engineering (FME)
Author: Arun Bhiva Rane

This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited


No metalworking process has the ability to form external and internal contours, shapes, cavities, and so foundry operation is important. Due to competitor’s pressure, metal caster’s has to refine current processes. They need to develop new technologies that improve productivity and reduce costs. Core-making is heart of metal casting. Core making process is one area, where foundries can improve process efficiencies and cost savings. This report investigates the possibilities and methods to reduce the time of the core production process in reputed casting company in order to increase the production. After understanding current process, bottleneck operations and root cause were identified. Most significant causes selected were; To reduce the cycle time of the machine, to eliminate the time lost in waiting due to unavailability of core sand, and to reduce the pattern changing time. Eighteen possible solutions were suggested. As per the suggested possible remedies, cycle time can be reduced by 17% to 35% while rate of production can be increased by 64% to 107% successfully by cold-box production system. Also Sand, resin, catalyst and additives can be metered precisely to improve quality. Thus higher quality cores can be produced by properly integrated core-production system. Operations can be automated to further improve the production and quality by observing trade-off between cost and productivity.


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