Continued from pg 25 3.2 Part Layout and Spacing Adjustments


A key component of the assembly optimization was adjusting the spacing between parts to increase part density. Manual processes often exhibited inconsistent spacing, which led to inefficient use of material and space. By automating the assembly process, we were able to standardize the layout and minimize part spacing. This adjustment allowed for greater part density within each assembly, ultimately reducing the total number of assemblies required to produce the same number of sellable parts.


4. Quantification of Scrap and Rework One of the primary objectives of the


study was to reduce scrap and rework. To achieve this, we closely monitored the scrap rates before and after automation and optimization were implemented. The baseline scrap rates, cycle times, and rework requirements were recorded to provide a comparison for evaluating the improvements post-automation. Automation of the injection and assembly processes aimed to reduce or eliminate human variation, stabilize process


variables, and reduce the


occurrence of defects. The reduction in scrap and rework was expected to result in significant material savings, labor reductions, and overall improvements in production efficiency.


5. Shell Room Integration In addition to operational


study was on wax room operations, we also


Although the primary focus of the considered


the downstream


effects of process improvements on the shell room. By reducing the number of assemblies required and increasing part density, the workload in the shell room was expected to decrease. The impact of these changes on shell material usage and labor


in the shell room


was monitored as part of the overall efficiency gains.


improvements, this study also examined the environmental impact of modernizing the wax room. Reducing scrap, rework, and material waste was expected to contribute to a more sustainable production process by lowering raw material consumption and energy use. As part of our methodology, we recorded energy consumption and material savings to evaluate the broader sustainability benefits of automation. By following this structured


approach, we ensured that the impact of each phase of the optimization


26 ❘ February 2025 ® Figure 3: Shells for Different Part Quantities


6. Environmental and Sustainability Considerations


process was carefully measured and


compared against the baseline data. This methodology allowed us to demonstrate the operational and environmental benefits of automating wax room processes in investment casting foundries.


Results The results of this study demonstrate significant improvements in wax room operations after the implementation of automation and process optimization. These results are broken down into several key areas, including increases in injection capacity, reductions in scrap and rework, improvements in assembly efficiency, and material savings. The


Table 3: Shell Material Savings and Labor Efficiency


Figure 2: Increase in Part Density and Reduction in Assemblies Required


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