Feature Article Eagle, Continued from pg 27
produce a solution, like preparing to reroute the production process through a replacement channel when needed. On the basis of continuous
improvement, EPCP has made several major investments in recent years that have significantly improved aspects of our production.
Wax Room EPCP set out to boost the efficiency of creating the wax molds we use in investment casting, and two new practices have shown significant results:
Die Design We were determined to find a way to cut down on the time per job that the die is being run on the press, which simultaneously reduces labor hours and the risk of damaging the die. The solution we found was to migrate from single-cavity tooling, which requires a good deal of manual input, to semi- automatic multi-cavity tooling. Thanks to our new semi-automatic multi- cavity dies, much of the wax injection and ejection process is automated.
Yield Improvement On an audit, one of our employees spotted an opportunity: by increasing the number of wax molds we attach to a single tree, we can improve overall throughput. With a few modifications, our trees are now lighter and can carry more pieces per tree. The efficiency gains here are obvious: more pieces per cycle, and less ‘wasted space’ per tree.
Robotic Cells
EPCP has been employing two robotic cells that exemplify the advantages that continuous improvement can bring to a factory floor. When deployed in their optimal setting, robotics can bring enormous cost and quality benefits to a factory.
Robotic Dipping Cells EPCP employs a Fanuc articulated robot arm in the dipping process.
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This means that, instead of a manual operator holding the pattern tree in the mixing tank to cover it in slurry, the Fanuc arm holds the pattern tree in the tank before ridding the tree of excess slurry and transferring it to the sander. Once the tree is adequately sanded, the Fanuc arm hangs the sanded pattern tree on a nearby rack.
Robotic Grinding Cells
Our enthusiasm for furthering efficiencies in the investment casting process with robotic cells does not stop at the dipping tank. Grinding is an essential after-cast process, and one that is a perfect candidate for automation. Our robotic grinding cell consists of a Fanuc pick-and-place arm, and a RGS230 Revolving Table Grinder manufactured by AW Bell Machinery.
What Continuous Improvement Means for Investment Casting Customers The ultimate goal is to save time and money, all while creating a superior product with shorter cycle times, carrying fewer defects and variations. The process of constantly refining
and optimizing production leads to higher quality products, faster delivery times, and cost savings that get passed on to customers. Most importantly, continuous improvement increases reliability. Customers of factories that employ continuous improvement can expect their parts to be delivered on
time, every time, and with minimal returns. While setup costs may be less for companies, the lifetime cost of a project can be exponentially higher if processes aren’t optimized factory-wide. Additionally, all companies within the Eagle Group, including Eagle Precision, are ISO-certified. With that certification comes responsibility towards continuous improvement and lean manufacturing. Embedded in the ISO certification process is an analysis of how a company designs their ‘Process Approach to Continuous Improvement’. What this means on a go-forward basis is that evaluations are constantly being made to determine whether the attempted improvements have in fact resulted in yield improvements. As a result, customers can rest assured that improvements in the cost basis of a precision part are also being passed through to them. By benefitting from products that are more reliable and cost- effective, continuous improvement is a win-win for both manufacturers and customers. Through tried-and-tested systems
that reduce waste and optimize processes, manufacturers like Eagle Precision Cast Parts not only enhance their production capabilities but also deliver superior products to customers. This ongoing commitment to improvement ensures that customers benefit from higher quality products, faster delivery, and better overall value.
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