After optimization, parts produced per hour increased from 257 to 322, a gain of 25%. Simultaneously, the scrap rate dropped from 52% to 4%, representing


a 92% reduction Table 4: Metal Savings by Increasing Part Density


in defective parts. This improvement reduced the number of rework cycles and led to a decrease in the number of injections required, from 1,152 to 692. The overall reduction in cycle time also contributed to increased production efficiency.


2. Assembly Efficiency and Labor Savings


The automation of the assembly


process resulted in a significant reduction in the number of assemblies required, as well as labor savings. By automating the layout and spacing of parts, we increased the part density within each assembly, which reduced the total number of assemblies required and decreased the amount of time spent on manual assembly. Automation increased the part density from 80 parts per assembly to 90 parts, resulting in a 12.5% reduction in the number of assemblies required to produce the same number of parts. This led to significant labor savings, with 44.5 hours saved over the course of the production run. Additionally, reducing the number of assemblies produced saved approximately 29.5 pounds of wax, contributing to both cost savings and a reduction in material waste.


3. Shell Material Savings and Downstream Benefits


Figure 4: Metal Pour


data collected across five part numbers shows that the automation of wax injection and assembly processes not only increased production capacity but also reduced labor and material costs. Additionally, the environmental impact of the process improvements was evaluated,


demonstrating substantial


material savings and a reduction in energy consumption.


1. Gains in Injection Capacity and Scrap Reduction


The automation of the wax injection


process led to significant gains in production capacity and a notable reduction in scrap rates. By automating the injection process and controlling all injection parameters, we were able to achieve consistent part quality, drastically reducing the number of defective parts.


®


The improvements in the wax room had a direct impact on the shell room, where the increased part density and reduction in the number of assemblies required led to a decrease in shell material usage. The automation of wax room processes also allowed for more parts


to be included in each mold,


which reduced the overall number of molds needed.


By increasing the number of parts per mold from 80 to 90, we saved a total of 826 pounds of shell material and


Continued on pg 28 February 2025 ❘ 27


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