ing machine can mean the difference between you controlling the process and the process controlling you. Analyzing and upgrading the existing configuration can optimize existing machine performance. Beyond getting an old machine to perform better, equipment can be modernized to meet new customer and regulatory requirements as a via- ble cost-effective alternative to a new machine. Over time, as new technol- ogy is introduced for the specific pur- pose of productivity improvements or ease of maintenance, it becomes increasingly important to evaluate investment in equipment upgrades. Te bottom line is a simple equa-
tion: Value = Benefit – Cost. If the current operational costs are unknown, then the benefit of process improve- ments are hard to justify. Reluctance to change is understandable without clear evidence on how one poor practice impacts cost elsewhere. Mapping the landscape allows you to make an informed choice. Benefits for process controls and
equipment upgrades will mean one of two things if done properly. 1. Current throughput at a lower cost with improved quality.
Analyzing the process end-to-end and putting figures and cost against every parameter will ensure the right adjustments are made to procedures and equipment.
requirements?
• How are secondary operations impacted?
• What are the major operational problems with the current equip- ment, resulting in higher costs per part or an inability to meet output targets?
• Has the product changed (with regard to dimensions, complexity, type or surface specification) such that it cannot be handled by the current setup? Once you’ve identified the issues,
determine which can be solved using process control improvements and which might require new or upgraded equipment or other modi- fications. It’s usually a smart combi- nation of actions that produces the greatest productivity improvements and cost reductions.
Step 4. Plan for the Future Bear in mind that a lot can be
achieved through equipment mod- ernization. Simply adding an abrasive adder and separator to a blast clean-
SPOT THE SIGNS
Here are some of the most common causes of poor performance specific to blast equipment: • Improper abrasive additions. • Low blast wheel amps. • Blast wheel targeting issues. • Abrasive leaks and waste from improper adjustments. These performance issues have the potential to cause:
• Inconsistent blast wheel amps. • Hot spot shifts. • Finish changes and fluctuating line speeds. • Increased cycle times to meet specifications. • Loss of process control.
October 2013 MODERN CASTING | 33
2. Additional throughput with improved quality in the same operational timeframe, resulting in more sales. Every foundry is in business to
deliver great value to customers, and improving margins by correcting or improving operational practices and equipment is a natural part of that.
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