Technical Paper


Versatility and Cost Savings Through Modernization of the Wax Room


by Aaron Phipps, MPI, Inc. Abstract


T


his paper explores the significant operational


gains, cost savings,


and material efficiencies realized through the modernization of the wax room using automation and precision process control. Collaborating with Lamothermic, Tech Cast and one other foundry who opted to remain unnamed, we conducted a comprehensive analysis of five different part numbers. Our efforts focused on increasing production capacity, reducing scrap, and optimizing material use throughout the downstream process through improvements in wax injection and assembly processes. This paper quantifies the results,


demonstrating notable labor savings, material


reductions, and improved


workflow efficiencies. We also reference findings from a previous MPI study, highlighting how modern technology addresses operator variability and enhances downstream processes.


Introduction The manufacturing industry is facing unprecedented pressure to meet rising demand while navigating


And-Retain” World), we explored the transformative impact that smart automation has on employee training and retention. This study showed that by allowing the machine to own the processes, foundries could significantly boost productivity and reduce costs while creating a more engaging work environment. However, that work was only the beginning. In this paper, we take a


the dual


challenges of a shrinking skilled labor pool and escalating labor costs. For foundries, these challenges can be critical bottlenecks in the production process. Wax


room operations, traditionally


reliant on manual processes, are prone to variability, overprocessing, and high scrap rates. These inefficiencies not only drive-up operational costs but also slow down production, making it increasingly difficult for foundries to stay competitive. In response to this, modernizing the wax room has become a necessity. In our previous study (How


Automation Can Be Used as an Employee Development Platform and Cost-Saving Tool in the New “Difficult-To-Hire-


24 ❘ February 2025 ®


comprehensive look at the broader impact of modernizing wax room operations, with a particular focus on both efficiency and sustainability. In collaboration with three foundries, including Lamothermic, Tech Cast and one other foundry, we analyzed five part numbers to quantify the gains in production capacity, material savings, and labor efficiency achieved through automation. What sets this study apart from previous efforts is our focus on sustainability—how modernizing the wax room can not only drive down operational costs but also significantly improve yield and throughput. As industries move towards more sustainable practices, the role of automation extends beyond operational efficiency. By automating key wax room processes, we reduce the amount of scrap material, lower rework rates, and reduce material and labor consumption through the entire foundry process. This translates into less wasted wax, shell material, and metal, while also cutting down on the labor required to produce sellable parts and recycle excess materials. The net effect is more sellable parts per hour, at lower material and labor costs.


Methodology This study aimed to assess the operational improvements and sustainability benefits


of modernizing wax room processes through automation and process optimization. The methodology followed a structured approach, beginning with baseline assessments of the customers' current processes, optimizing injection parameters and isolating them from operator changes, followed by


the


implementation of automation and standardized workflows, and concluding with a comprehensive evaluation of the improvements in production efficiency, material usage, and labor savings.


1. Customer Collaboration and Baseline Establishment


establish a baseline


The first step of the study was to for


the existing


wax room processes at each customer facility. Our customers selected five different part numbers for evaluation, each with varying geometries, weights (ranging from 0.2 to 0.6 pounds), and production volumes (between 250 and 15,000 parts per run). These part numbers represented typical injection and assembly challenges in wax room operations. To gather baseline data, we worked closely with the customers to document their current wax injection and assembly processes. MPI’s 20-20 process vision system allows real time monitoring and measuring of actual process parameters (temperature, pressure and flow) on any wax injector. Utilizing the 20-20, we were able to document the exact injection process on their equipment. We also collected key performance metrics, including scrap rates, cycle times, number of injections, and labor requirements for each part. This initial assessment allowed us to identify inefficiencies in manual operations, such as high variability in injection quality,


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