T is situation also highlighted the importance of
documentation and evaluation of the information
gathered during the process.
operator would ram a layer of plastic material from the tip of the spout to the inside of the furnace to elimi- nate the seam as an avenue for metal penetration. T is method off ered some
improvement but was diffi cult because of molten metal in the furnace. T en, on the daily drain off , the operator did a better job of ram- ming in the plastic that was covering the area. T is appeared to solve the problem. Apparently, as long as the operators properly rammed the plas- tic, penetration could be prevented. In addition to what had been
learned, the company experienced several benefi ts that were direct results of the investigation: • Elimination of the dangers of metal penetration behind the lin- ings with the risk of penetrating to the coil (a major safety issue).
• A 15% increase in melted tonnage per lining campaign.
• Improved refractory material. • Improved furnace repair practices. • Employee education on proper furnace repairs. T e resolution to Motor Cast-
ings’ problems could not have been accomplished without the help of
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Find the original research paper at
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experts outside of the organization. T is situation also highlighted the importance of documentation and evaluation of the information gath- ered during the process. T e analyti- cal skills of the employees improved because they were heavily involved in the entire process. T e answers to the
problems were not new or something unknown to the industry. However, this case study reinforces the need for continual training and development of internal staff . This article is based on paper 14-025 presented at the 2014 AFS Metalcasting Congress.
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