productivity improvement of sand casting industry

8/18/2019 Productivity Improvement of Sand Casting Industry

1/59

Productivity Improvement of Non Ferrous FoundryA Project Report

Submitted by

VATSAL DOSHI

JINAL LAD

OHA! "HTA

PALASH SRIVASTAVA

Under The Guidance Of

Prof#$#J D"SAI

in partial fulfilment for the award of the degree

Of

$A%H"LOR OF T"%HNOLO&'

IN

"%HANI%AL "N&IN""RIN&

(t

)!"SH PAT"L S%HOOL OF T"%HONOLO&' ANA&" "NT AND"N&IN""RIN&*

SV! +s N I S )NIV"RSIT'* ) $AI

APRIL ,-./


2/59

%"RTIFI%AT"

This is to certify that the project entitled “ Productivity Improvement of Non Ferrous Foundry ” is

the bonafide work carried out by V(ts(0Dos1i* Jin(0 L(d* o1(2 e1t(* P(0(s1 Sriv(st(v( of

B.Tech(Mechanical Engineering) M!"TME (#M$M") Mu%bai during the &$$$ se%ester of the

acade%ic year ,-.34,-./ in partial fulfil%ent of the re'uire%ents for the award of the egree of

Bachelors of Engineering as per the nor%s prescribed by #M$M". The pro ject work has been

asses sed and found to be satisfactory.

Prof. B.J Desai

Internal Mentor

Examiner 1 Examiner 2

Dean

Dr.S.Y.Mhaiskar

D"%LARATION


3/59

e V(ts(0 Dos1i* Jin(0 L(d* o1(2 e1t(* P(0(s1 Sriv(st(v( Ro00 No# F-..* F-,.* F-,5*

F-67 of B.Tech (Mechanical Engineering) &$$ se%ester understands that plagiaris% is defined as

anyone or co%bination of the following*

+. ,n-credited erbati% copying of indi idual sentences paragraphs or illustration (such asgraphs diagra%s etc.) fro% any source published or unpublished including the internet.

/. ,n-credited i%proper paraphrasing of pages paragraphs (changing a few words phrases orrearranging the original sentence order)

0. 1redited erbati% copying of a %ajor portion of a paper (or thesis chapter) without clear

delineation of who did wrote what. ("ource* $EEE The institute ec. /223)

3. $ ha e %ade sure that all the ideas e4pressions graphs diagra%s etc. that are not a result of%y work are properly credited. 5ong phrases or sentences that had to be used erbati% fro%

published literature ha e been clearly identified using 'uotation %arks.

6. $ affir% that no portion of %y work can be considered as plagiaris% and $ take full responsibilityif such a co%plaint occurs. $ understand fully well that the guide of the se%inar7 project report %aynot be in a position to check for the possibility of such incidences of plagiaris% in this body ofwork.

"ignature of the "tudent*

#a%e* &atsal oshi 8inal 5ad Mohak Mehta !alash "ri asta a

9oll#o.:2++ :2/+ :2/0 :23;

!lace* Mu%bai

ate* /+


4/59

A%!NO8L"D&" "NT

$t>s our pleasure to thank our De(n Dr#S1r(d '# 1(is2(r for his encourage%ent and support.

?is positi e approach has always been a guiding spirit for all our research and de elop%ent.

e wish to e4press our sincere gratitude to our project guide Prof# $ J Des(i for his guidance

encourage%ent and support throughout our project. e %ust thank hi% for guidance and ut%ost

attention on arious journal and presentations. ?is constant e aluation on our project and

collaboration of apt solutions has helped us to conclude with inno ati e ideas and results.

e would also like to thank the owner of the #on :errous :oundry r#!is1or e1t( for his

constant support technical guidance acceptance and patience for our professional re'uire%ent.

1


5/59


6/59

T(90e of %ontents

5ist of Tables............................................................................................................................@...+

5ist of :igures..........................................................................................................................@.../


7/59


8/59

List of T(90es

%HAPT"R TITL" PA&" NO#+. $#T9D ,1T$D#/. 1


9/59

%HAPT"

R TITL"+. $#T9D ,1T$D#

/. 1


10/59

:ig0./+*"a%ple of proposed Mould bo4:ig0.//* "tacking of Mould bo4es:ig0./0* 1< %odel of Mould bo4es on hanger :ig0./3* 1urrent !osition of %oulder while %oulding:ig0./6* !osition of %oulder working on 9oller orkbench:ig0./=* "ketch 5ayout of Moulding


11/59

%1(pter; .

Introduction

.#. A9out Non Ferrous Foundry

#:: is a casting %anufacturing co%pany founded by "hree heerajlal Mehta in the year +;A2.

1urrently under Iishor Mehta since /22+. The foundry is located in &api Cujarat. $t

%anufactures %ajorly 1$


12/59

0. !u%p Body

3. !late type !ulley

6. Motor 1o er

=. :ire Bar

A. "ewage 1o er

. $ngot

;. Dther general purpose products like Bush 9od

1ircle "'uare block 1$ ?and wheel 9ing.

%1(pter ,

%(stin: Processes

,#. A9out %(stin:

1asting is a %anufacturing process in which %olten %etal is poured or injected and allowed to solidify in

a suitably shaped %ould ca ity. uring or after cooling the cast part is re%o ed fro% the %ould and then

processed for deli ery. 1asting processes and cast -%aterial technologies ary fro% si%ple to highly

co%ple4. Material and process selection depends on the partHs co%ple4ity and function the productHs

'uality specifications and the projected cost le el.1astings are parts that are %ade close to their final

di%ensions by a casting process. ith a history dating back =222 years the arious casting processes are

in a state of continuous refine%ent and e olutions technological ad ances are being %ade.

2


13/59

Fi:#,#. Pourin: in c(stin: Fi: ,#, So0idific(tion in c(stin:

4

,#, F0o< process c1(rt

3


14/59

Fi: ,#5 F0o< process c1(rt

,#5 e0tin:

4


15/59

,#5#. Furn(ce used in NFF4 %upo0(

The cupola is basically a cylindrical shaft furnace that burns coke intensified by the blowing of air

through no les.


16/59

,#6#. &reen S(nd ou0din:

Fi: ,#3S(nd f0o< c1(rt

$t is one of %any %ethods a ailable to the foundry %an for %aking a %ould into which %olten %etal can

be poured. Creen sand %oulding and che%ically bonded sand %oulding are considered to be the %ost

basic andwidely used %ould %aking processes. Creen sand %edia are prepared by coating the grains of

sand with binder that is later shaped into a rigid %ass by the application of force. Creen sand %oulding is

the least e4pensi e fastest and %ost co%%on of all the currently a ailable %oulding %ethods. The

%i4ture of sand and binder can be used i%%ediately after the %i4ing process that coats the sand grains.

,#6#, $(tc14Type u00er

6


17/59


18/59

,#3#. Type of P(ttern

Loose p(tterns* also called one-piece patterns or solid patterns are the si%plest least e4pensi e type of

reusablepattern and are suited only to ery low-'uantity production. This type of pattern is %ost

appropriate for e4peri%ental or prototype castings and is only rarely used for short-run production

castings. Moulding with a loose pattern re'uires %ore %anual operations and a %uch higher degree of

%oulder skill than %oulding with other pattern types. Manyfoundry%oulding depart%ents are not set up

to use loose patterns. This increases the cost per %ould and results in ariations in casting 'uality fro%

%ould to %ould co%pared to %ould%aking with other pattern types. < loose pattern can be %ade in one

piece or in two pieces (split patterns). The split in the two-piece pattern corresponds to the parting line in

thepattern. Dne-piece loose patterns are often used when one side of the pattern is a flat plane that can

ser e as the parting line while two-piece loose patterns are %ore co%%only used when the shape to becast is %ore co%ple4.Moulding with one-piece loose patterns often re'uires considerable ti%e and skill

on the part of the %oulder

.

Fi: ,#> Loose p(ttern of (n I% en:ine c(sin:

,#3#, P(ttern H(nd0in: (nd Stor(:e

Because significant in est%ents are %ade in pattern e'uip%ent pattern handling and storage %ust be

carefully considered by the foundry. $%proper storage and handling can cause pattern deterioration and

da%age particularly for wood patterns because hu%idity and te%perature changes can cause se ere

distortion. The foundry typically has %any patterns in in entory. Dbsolete or discontinued patterns should

be routinely destroyed to %ake roo% for new patterns.

!


19/59

Fi: ,#7 Storin: of pump 9ody p(ttern in NFF

,#/ ou0d (2in: Process ?AS @

The se'uence begins with a %echanical drawing of the desired part. !atterns are then produced and

%ounted on pattern plates. Both the cope and drag patterns include core prints which will produceca ities in the %ould to acco%%odate e4tensions on either end of the core. These e4tensions fit solidly

into the core prints to hold the core in place during pouring. The gate or passageway in the sand %ould

through which the %olten %etal will enter the %ould ca ity is usually %ounted on the drag pattern plate.

5ocating pins on either end of the pattern plates allow for accurately setting the flask o er the plate. 1ores

are produced separately by a ariety of %ethods. The core bo4es which are ra%%ed with a %i4ture of

sand and core binder. $f the cores %ust be asse%bled fro% separately %ade co%ponents they are pasted

together after curing. They are then ready to be inserted into the sand %ould. The %ould is %ade by

placing a flask (an open %etal bo4) o er the cope pattern plate. Before %oulding can begin risers are

added to the pattern at predeter%ined points to control solidification and supply li'uid %etal to the casting

to co%pensate for the shrinkage that takes place during cooling andsolidification. Thus any shrinkage

oids for% in the risers and the casting will be sound. < hole or holes (called sprues) %ust also be for%ed

in the cope section of the %ould to pro ide achannel through which the %olten %etal can enter the gating

syste% and the %ould ca ity.

The cope half of the %ould is produced by ra%%ing sand into the flask which is located on the pattern

plate with pins. The flask full of sand is then drawn away fro% the pattern board and the riser and sprue

pieces re%o ed. < flask is subse'uently placed o er the drag pattern plate using the locating pins on the

plate. "and is ra%%ed around the pattern and a botto% board is placed on top of the flask full of sand.

The pattern flask and botto% board are then rolled o er + 2J and the pattern is withdrawn. The

"


20/59

co%pleted core is set into the core prints in the drag half of the %ould and the cope half of the %ould is

set on top of the drag. !roper align%ent of the %ould ca ity in the cope and drag portions of the %ould is

ensured by the use of closing pins which align the two flasks. The flasks can be cla%ped together or

weights can be placed on top of the cope to counteract the buoyant force of the li'uid %etal which would

otherwise tend to float the cope off the drag during pouting. Metal is then poured into the %ould ca ity

through the sprue and allowed to solidify. The casting is shaken fro% the sand and appears with the

sprue gating syste% and risers attached. :ollowing shakeout the flasks botto% boards and cla%ps are

cycled back to the %oulding station while the casting is %o ed through the production process. hen the

gates and risers are re%o ed fro% the casting they are returned to the furnace to be re-%elted.


21/59

Fi: ,#..$(sic steps invo0ved in m(2in: ( c(stin: from ( :reen s(nd mou0d

11


22/59

%1(pter 5

Study (nd An(0ysis

5#.Scope of Study

$n our "tudy we used /2- 2 rule which states that “ 2K of the effects or proble%s co%e fro% /2K of the

causes”. "o we focused on the %ost crucial process of casting where a %inor i%pro e%ent can cause a

%ajor change .The !rocess is Moulding

uring the study we focused on the factors affecting the producti ity related to %oulding process which is

the scope of our study.

e do not intend to change the process7operations followed by the co%pany since 36 years to produce their

'uality casting but we intend to study analyse and suggest a different way of doing the sa%e

process7operation in order to produce opti%i ed output.

12


23/59

5#, 8or2 study

$t is the syste%atic e4a%ination of the %ethods of carrying on acti ities so as to i%pro e the effecti e use

of resources and to set up standards of perfor%ance for the acti ities being carried out.

5#,#. Procedure;

Fi: 5#. 8or2 Study Procedure 2B

13


24/59

a) "elect*

:or studying %oulding process we classified job to be studied in 0 categories that is s%all %ediu% and

large si e castings .$n the plant generally for e ery +2 casting jobs A are s%all si ed casting / are %ediu%

si ed and + is large si ed casting as been infor%ed by !lant %anager of the co%pany.

"o we selected = rando% s%all si e casting one %ediu% si e casting and one large si ed casting as our

subject to study %oulding process

b) 9ecord*

:low !rocess 1hart was %ade and used in order to record ti%e taken and distance tra elled by worker in

co%pleting a process

Tools for recording data used were stop watch and %easuring tape .The readings were jotted downsi%ultaneously onto the chart while the worker was perfor%ing the operation of %oulding of jobs under

study.

c) E4a%ine*

E4a%ination of each and e ery process was done carefully taking in account of the ti%e and effort being

put up and also loss7wastage of %aterial being done during the act.

e focused on few processes where effort %ade and ti%e consu%ed can be reduced

:ro% the obser ation we found that with a little re%edial action or a little %odification here and there in

few of the processes a drastic reduction in %aterial handling ti%e consu%ption and wastage of %aterial

could be achie ed.

d) e elop*

e tried to de elop this by taking in to reference few co%panies like !anchal foundry

e e en took suggestion fro% workers who are working in the industry

e took ideas about the way the processes were perfor%ed fro% a co%pany na%ed "pring 1ity Electrical

Manufacturing :oundry Lo which e4ports their products in international %arket through FouTube ideos.

e used


25/59

The results which we ha e obtained and the new %ethods which we ha e suggested are e4plained in

detail in ne4t chapter.

5#5 F0o< Process %1(rt

Fi: 5#, F0o< process c1(rt pB

15


26/59

Fi: 5#5 Se0f4m(de process c1(rt

$ts features are* Table can help


27/59

5#6 R(mmin: Process

5#6#. Definition (B

This is a process in which striking of the %oulding sand %ass is done in the %oulding bo4 to pack

unifor%ly around the pattern. The co%%on for%s of ra%%ers used in ra%%ing are hand ra%%er peen

ra%%er floor ra%%er and pneu%atic ra%%er.

5#6#, %urrent Pr(ctice

(nu(0 R(mmin: is hea y and difficult to use. < lot of energy and ti%e is in ol ed with a erage

perfor%ance. The hea y ha%%er da%ages the %ould bo4es with se eral inaccurate blows. Dn-unifor%

load distribution and co%pression on sand leads to poor 'uality of %ould.


28/59

Earth 9a%%er weight around 6.3kgs re'uires effort to lift and drop continuously. Cood !hysical strength

is re'uired.

Fi: 5#3 "(rt1 r(mmer on t da%age the %ould bo4es while

ra%%ing.

1!


29/59

Fi: 5#/ Pneum(tic r(mmer Fi: 5#= Pneum(tic r(mmer durin: oper(tion

5#6#6 %ost "stim(tions dB

1osts* "teel !neu%atic 9a%%er* 9s+/ 622 N eli ery charges

1o%pressor and Tank* 9s = 22= N eli ery 1harges


30/59

This %ethod to re%o e pattern re'uires skill of tightening the wire around pins as well as deciding the

points to be inserted into pattern to %aintain balance while lifting the pattern.

$f the pattern is to be re-used then pins has to be inserted again but at different pointwhich causes da%age

to the pattern on longer run.

S2i0fu0 remov(0 of p(ttern from mou0d eB

5#3#5 Proposed Tec1niCue

,se 5-tool as shown in figure ha ing a sharp point at one of its end. $t has screw treads on that end to

engage with wooden pattern for its withdrawal fro% the %ould.

2#


31/59

5#3#6 Adv(nt(:es of Proposed Tec1niCue

• Eli%inates the repetiti e action of inserting nails7pins in pattern thus reducing pattern da%age.

• $t is ery easy to use .8ust screw the tool in pre-screwed point into pattern and pull it.

• This techni'ue speeds up the work of re%o ing pattern co%pared with current practice.

• "kill isn>t re'uired to do the abo e task using 5-tool.

• uring batch production of any casting. The !attern has to be used %ultiple ti%es. $n such cases

this %ethod ser es as an ideal way of re%o ing pattern fro% %ould as the pre-screwed point can

used se eral ti%es to re%o e it.

• The proposed %ethod reduces %ould da%age while lifting the pattern unlike currently used

techni'ues.

Fi: 5#7 %(d mode0 of L too0 Fi: 5#.- Remov(0 of p(ttern usin: L too0 6B

21


32/59

5#3#3A0tern(te propos(0 su::ested e9(B

Tool #a%e* "uction ent !uller

"pecification*

ia%eter* 3-+7/O 1apacity* ++2 5B


33/59

• 1orrosion resistant because of alu%iniu% body

• Easy to use as skill isn>t re'uired %uch co%pared to abo e %entioned techni'ues

•

oesn>t da%age %ould ca ity while lifting pattern.

• ?igh lifting capacity up to 62kg

• oesn>t re'uire any ta%pering with pattern.

Limit(tions of suction cup;

• The surface has to be free fro% any sand particles and cleaned before using the suction cup

• The geo%etry of the pattern should be such that inner surface of the cup should not be e4posed to

air when the cup is pressed onto pattern surface with the help of the handle .This will create proper

suction between contact surface.

5#/ Supp0yin: S(nd to ou0der

5#/#. A9out Process;

uring %oulding process %oulder re'uires green sand e ery now and then for filling up the %ould bo4

tightly so pattern fi4es up fir%ly which prints the shape of ca ity with close di%ension. ith the currently

used container for holding green sand the worker needs %ini%u% three to four container full of sand for

filling up s%all %ould bo4 .5ikewise =-A container of green sand to fill up %ediu% si e %ould bo4.

The supply of sand to%oulder is done by ?elper or if helper is indulge in so%e work then %oulder has to

fill the sand container by hi%self and take it back to %oulding spot.

Each container of sand weighs around +3.6kg and contains 6.6 litres of green sand in olu%e.

23


34/59

These sand filled containers are filled and carried by helper7%oulder (as shown in fig) and then

transported fro% sand churner to %oulding spot.

Fi: 5#., He0per fi00in: t1e cont(iner Fi: 5#.5 He0per tr(nsportin: t1e s(nd cont(iner

5#/#, Need for Optimi (tion;

$n the process7operation of supplying sand drawback seen is that helper7%oulder has to carry container

right fro% sand churner till %oulding area %anually .Moreo er %ini%u% 0 rounds of supply are needed

with use of such container. The round of supply increases with increase in si e of %ould bo4 used for

%oulding.

The %oulding point is not fi4ed but it keeps on changing as place%ent of %oulds is done one by one.

"ince %oulding point is not fi4ed so will be the %o ing path of %oulder where it %ay so%eti%e occurthat %oulder finds difficulty in passing carefully across ready-to-pour %oulds in plant. This adds to ti%e

spent on co%pleting the whole process.

9ounds of supply can be reduced by supplying %ore sand at once co%pared to currently used container.

"o there was a need for opti%i ation process by fi4ing the abo e issues.

24


35/59

5#/#5 Su::estion

e suggest the% to use a different container which carries %ore olu%e of green sand so as to decrease

the fre'uency of supply.


36/59

Fi: 5#./ S(nd cont(iner on t ha e a good

handle to carry. "o%eti%es due to its geo%etry the sand %ay fall out of container while transporting.

Ro00er %onveyer for Tr(nsport(tion of s(nd;

This con eyor should be installed within the plant near to sand churner and stretched towards “#ew

Moulding


37/59

Dn this con eyor the helper needs to transport the sand filled container right fro% sand filling one

beside sand churner to #ew Moulding t re'uire electricity for its functioning. The rollers lie

on bearing support which helps in the s%ooth %o e%ent of the green sand.

By adopting abo e plan we can reduce workforce %o e%ent and %aterial %o e%ent.

$f new containers are used on con eyors for transporting green sand then it would decrease the

fre'uency of supply to %oulder. Thereby decreasing a lot of ti%e and effort put by workers in

transporting %aterial.

2


38/59

Fi: 5#.= &r(vity ro00er conveyor 9enc1 4EB

5#= Ne< ou0d $o

5#=#. Function of ( ou0d $o

Mould bo4 is use to pack the sand with the pattern such that close di%ension of the ca ity is obtained

when pattern is re%o ed fro% %ould bo4. The upper part of the %ould bo4 is 1ope and botto% one is

rag. Between 1ope and rag parting line e4ist inside the %ould bo4 where the %elt poured flows

through path %ade by %oulder while %oulding.

Mould bo4 pair should be accurately aligned and engaged such that there re%ains no gap between two

%ould bo4es. This ensures that sand doesn>t co%e out of %ould.

uring pouring these %ould bo4es e4perience %elt>s %etallostatic forces due to which the cope part starts

to repel fro% the drag. This causes leakage of %elt fro% the parting line after or during pouring if dead

weights are not kept enough.

2!


39/59

Fi: 5#.> %urrent mou0d 9o

5#=#, Re(sons to use Ne< ou0d $o

5eakage of Melt during pouring due to defor%ation of %ould bo4es which leads to dis-align%ent of

%ould bo4es. This dis-align%ent creates open space for the sand and %elt co%es out during pouring.

2"


40/59

Fi: 5#.7 e0t 0e(2(:e due to deform(tion (nd dis4(0i:nment of mou0d 9o p(ir

The worker face handling difficulties because the %ould bo4 ha e corroded and ha e thin cross section of

handle which gi es i%%ense pressure on the hands of worker while lifting it. Moulding sand slips out

while lifting %ould bo4 due to low adhesi eness between the inner walls of %ould bo4 and green sand.

9educed adhesi eness is due to corrosion on inner walls of %ould bo4.

Fi: 5#,- %orroded mou0d 9o es

5#=#5 Fe(tures of Ne< ou0d $o

3#


41/59

e suggested the% to use new %ould bo4 which can pro ide following features in order to pre ent the

abo e %ention issues currently the co%pany is facing with their present %ould bo4es. #ew Mould Bo4

%ust ha e following features*

• !roper Edges.

• 1orrosion resisti e.

• !roper align%ent.

• #o Cap or space after engage%ent of Mould Bo4es.

• "trong ?andles.

• Cood ?eat issipation.

• 9obust towards Mishandling.

Fi: 5#,. S(mp0e of proposed mou0d 9o oipB

31


42/59

1ost* 9s /=337ite%

"pecification*

"i e* 02240224+22%%

Brand #a%e* "M ou0d $o Stor(:e

1asting co%panies are constantly in a need of pattern e ery ti%e they start the process. "o organi ation

and handling of %ould bo4es is an i%portant aspect. But here currently the %ould bo4es aren>t properly

organi ed and do not ha e a designated storage place. This increases the ti%e to find one when needed. $t

also causes da%age to the %ould bo4 and its %isplace%ent as well.

32


43/59

Fi:5#,,; ou0d $o es in NFF

The new %ould storage area will help organi e all the %ould bo4es and in accessing the desired pattern in

ery less ti%e.

Fi: 5#,5 St(c2in: of mou0d 9o es Fi: 5#,6 %AD ode0 of 1(n:er

#ew Mould Bo4es %ust be stacked properly. The ones which are used regularly %ust be hanged on the

hanger as shown in the abo e figure for fast and easy access .This also organi es the %ould bo4es

effecti ely hence reducing search ti%e.

33


44/59

5#7 ou0din: Are(

Moulding area is a spot or place where the %oulder %akes %oulds using pattern green sand white sand

%ould bo4 ra%%ers and other %oulding and gate cutting tools

1urrently %oulder doesn>t ha e a dedicated %oulding area where he can work with all of the abo e

%aterials and tools in order to %ake %ould with higher producti ity in ter%s of ti%e spent on producing

each %ould.

Moulder has to fi4 a %oulding spot in the plant depending on the a ailable space in plant. Then he

collects pattern fro% pattern storage rack.


45/59

• Eli%inates the %aking of flat area before starting %oulding which %ay so%eti%e take 6%ins-

+2%ins.

•


46/59

Fi: 5#,3 %urrent position of mou0der


47/59

:ro% where the un-used sand is collected and dragged into the hole where the sand falls into the sand

Bo4 as shown in the %oulding


48/59


49/59

Fi: 5#,7 %urrent P0(nt L(yout

The abo e picture gi es a rough idea of the current plant layout. $n the plant there are two unusable

%achines because there is a need of e4cessi e %aintenance in these %achines so co%pany wish to re%o e

it fro% the plant. Taking that in consideration and also proposed new %ould bo4 storage and %oulding

area .There will be a %ajor change in the plant if all the abo e plan ise4ecuted in future.

Fi: 5#5- Non4oper(tion(0 s(nd c1urner (nd cupo0( furn(ce

3"


50/59

Fi: 5#5. Ne< P0(nt L(yout

4#


51/59

%1(pter 6

"v(0u(tion G %(0cu0(tion

6#. R(mmin: %(0cu0(tions

T(90e

6#. %omp(rison of 1(nd r(mmer (nd pneum(tic r(mmer

F


52/59

6#, "v(0u(tion of Removin: P(ttern from ou0d

The basic purpose of changing the current pattern re%o al was to a oid da%age caused to the

1a ity and to reduce the skill re'uire doing the task. The new techni'ue will help to re%o e

pattern fir%ly placed pattern in the %oulding sand 'uickly such that the di%ension of the ca ity

change is %inor and pattern da%age is reduced substantially co%pared to the current used

techni'ue.

6#5 (teri(0 (nd s total %o e%ent will decrease by =AK to + .=6 %etres for producing sa%e si e casting

as per study gi en below.

istance (%etres)1urrent 5ayout 6A. 3

#ew 5ayout + .=6Tra elling istance "a ed 0;.+;

T(90e 6#, Reduction of


53/59

Fi: 6#. current f0o< process c1(rt

6#3 odified F0o< process in p0(nt

Fi: 6#, odified F0o< process c1(rt

6#/ Incre(sin: %ont(iner %(p(city

43


54/59

Dld

1ontainer

#ew 1ontainer $ncrease in

Suantity

$ncrease in

1apacityMass 1apacity (kg) +0.6 kg /+. kg .0 kg =+K

Vo0ume %(p(city?m5@

2.2266 m5

.2++m5

2.2266 m5

+22K

Mass capacity has been slightly reduced to re%o e the weight of the container and account for

sand only.

T(90e 6#5 "ffects due to cont(iner c1(n:e

:ro% the table abo e we can deduce that there will be a considerate a%ount of decrease in

worker>s %o e%ent with a +22K increase in olu%e carrying capacity of the new container.

6#= Ne< ou0d $o %(0cu0(tions


55/59

(teri(0

?2:@ ?Rs@ ?Rs@%(st Iron +2=+62 /A.6 /; +; +/6Pi: Iron =/=62 0/.6 /2 0= +/6

F0u /; 0 2 ++ 2/2Tot(0 %ost

?Rs@

3; == /A2

e0t Le(2(:e %ost

?Rs@

33 /==

S(vin:s ?on me0t@

?Rs@

00AA2=

ou0d $o es %ost

?Rs@

6/ 2

"stim(ted S(vin:s

?Rs@

/ 3 /=

Ne< ou0din: Are(

6#/#. Dimensions of Ne< 8or2 $enc1 (nd %onveyor

5ength U /.6%

idth U 2.=%

?eight- 2.A6%

6#7"v(0u(tion of L(9our cost1urrently for %oulding the staff co%prises of 6 %oulder and / helper. $t is esti%ated that only 6

worker staff is enough to produce current output produced by staff of A.

"stim(ted S(0(ry S(ved of , 8or2ers

45


56/59

T(s2 A00otted St(ff

S(0(ryKd(y

?Rupees@

%urrent

St(ff

?


57/59

current practice7processes at #:: done its ti%e study and then e aluation of those processes was

done where we found #:: was lacking and %a4i%u% increase in producti ity could be achie ed

with as less in est%ent of ti%e and %oney as possible. e ha e reco%%ended a few changes in

the ra%%ing process where we sought to replace the hand ra%%er with pneu%atic ra%%er. $n

the pattern re%o al techni'ue we ha e suggested 5-shaped groo ed tool which decreases the

ti%e to do re%o e the pattern. e ha e designed a new plant layout which has reduced worker>s

%o e%ent and %aterial handling considerably and also changed the sand carrying container for

the sa%e purpose. e ha e also suggested the% to buy new %ould bo4es to cut short the

%aterial wastage by reducing %elting leakage during pouring process and also designed a new

storage area for the new %ould bo4es to help %aintain the% and access the% as 'uickly as

possible.


58/59

Ti%e is being considered for %aking a s%all casting. orker>s speed is considered to be 2.A%7s.

< erage ti%e for e ery process is being considered.

Mo e%ent is considered for a single co%plete process.

T(90e 3#. Fin(0 Resu0t

R"F"R"N%"S

L .Ceorge Ianawaty.(+;;/)> $ntroduction to ork "tudy>U$ndustrial 5abour Drganisation.

L .


59/59

L Lin2; http*77www.tole4o.co%7s%art-fabricated-%ould-bo4.ht%lVut%WsourcePbuy-on-dirGut%W%ediu%Pi%referralGut%Wca%paignPi%-buy pg 02

Lwww.ebay.co%

L youtube links
http://www.ebay.com/http://www.ebay.com/

productivity improvement of sand casting industry

Documents