in one of the toughest departments in a casting facility. For Koyama, outside suppliers of automated equipment
were too expensive or the technology didn’t fit the casting environment. As a result, the firm developed its own double- head automated grinders and has continued to develop the systems. Ten, in the late ‘90s, the development caught the eye of Sintokogio and Roberts Sinto Corp., which decided to partner with the metalcaster to develop and market these automated grinding systems in North and South America and China. For higher production components, Koyama has pushed
its cleaning and finishing a step further to include linear production lines that incorporate trim cells and automated grinding for one-piece flow through the facility (Fig. 3).
Environmental & Safety Initiatives Many Japanese metalcasters report they focus on the
environment and how their facilities influence it. Te envi- ronment is part of their management strategy and all their planning around technological or production advancements. As a result, environmental initiatives typically amount to 10% of any annual investment in a facility. “Te Japanese mindset is focused on the environment
more than others,” Koyama said. In the new and old iron facilities, hoods to capture
emissions are present on all furnaces, pouring ladles, mold conveyors and cooling lines. In the new iron facility, the dust collection system as a whole processes a total air volume of 12,000 cu. m/minute.
发了双头的自动打磨床，并且不断地改进这个打磨系 统。然后在90年代末，该工艺改进吸引了新东公司和 Roberts Sinto公司，他们决定和Koyama公司合作改进 这些自动打磨系统，并将其销售到北美、南美和中国。 为了实现更高的生产部件效率，Koyama公司把清 理系统推进一步，组成线性生产线，包含修剪和自动打 磨，方便单件在车间里快速流动（图3）。
环保与安全举措
很多日本铸造厂声称他们专注于环保和他们的车间如 何影响环境。环保是他们围绕技术与生产进步的管理策 略和整体规划的一部分。这导致了环保措施通常占铸造 厂任何年度投资的10％。 Koyama公司声称，日本人比别人更加重视环保。在 现代与传统的铸铁车间，所有熔化炉、浇包、铸型输送 与冷却线都有捕捉排放的抽烟机。在现代铸铁车间，粉 尘收集系统一分钟收集的风量总共有12000立方米。 从安全角度看，Koyama公司跟许多别的日本铸 造厂一样，在熔融金属液转移时播放儿童音乐而不是 喇叭，来向员工警报潜在的危险。Koyama公司在生 产进步时和其它环保与安全举措一样也专注于减少噪
Fig. 3. Koyama uses automated linear clean- ing lines for higher production runs.
图3.Koyama公司利用 自动线性清理线来提高 生产效率。
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION Fall 2011
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