A four section hands-on lecture series designed to reduce waste, improve cost efficiency, and provide a universal education for foundries and their suppliers.

 

Day 1 -

Section 1  Raw Material Selection & Control

Section 2  Raw Material Conversion: Recycle for Profit

 

Day 2 -

Section 3  Sand Control: Green Sand & Resin Binder Systems

Section 4  SPC: Fundamentals of Statistical Process Control

 

One thing is for certain, knowledge brings any organization strength. As responsibilities expand in today’s economy, it is critical that all employees have the tools necessary to perform when needed. This workshop is designed for all disciplines within your organization:

 

Purchasing

Sales Personnel

Controllers   

Managers

Process Engineers

Supervisors

Melting Personnel

Industrial Engineers

Sand Technicians

Quality Technicians

Facilities Engineers

Customer liaisons

 

Section 1 - Raw Material Selection & Control

 

Metallics & Alloys

 

1.      Cost, Not Price

·         Understanding melt loss

 

2.      Cleanliness & Sizing

·         Are you buying the right grade?

 

3.      Chemistry

·         What are you paying for?     

 

4.      Delivery, Packaging & Inventory

·         What suits your process?

·         Is there a cost of inventory?

 

5.      Incoming Inspection & Certification

·         Developing your supplier relationship

 

6.      Material Specification

·         What to inspect for

 

Section 2 - Raw Material Conversion: Recycle for Profit

 

Charging Practices

 

1.      Storage & Inventory

·         Reduce waste

·         Usage reporting

 

2.      Method

·        Is the order important?

·        Chemistry control

·         Cupola and electric

 

          Melting & Alloying Practices

 

1.      Process

·         Timing is everything

·         What is important?

 

2.      People

·         Who does what?

·         Safety

          Molten Metal Preparation & Delivery

 

1.      Process

·         Slag and melt loss

·         Quality assurance

·         Delivery:  Temperature costs money

 

Section 3  Sand Control: Green Sand & Resin Binder Systems

 

          Raw Material Control: Sand & Binders

 

1.      Incoming Inspection & Certifications

·         What is necessary?

 

2.      Shape & Sizing

·         Inspection

·         What should it be?

 

3.      Delivery, Packaging & Inventory

·         Know what you are paying for

 

4.      Material Specifications

 

Green Sand

 

1.      Process

·         Specifications

·         Additions and timing

·         Testing methodology

 

2.      Quality assurance

·         Methods

·        When and where to test

 

Resin Binder Systems

 

1.      Process

·         Specifications

·         Calibration

·         Testing methodology

·         Binder levels

 

Section 4  SPC: Fundamentals of Statistical Process Control

 

Fundamentals

 

1.      Charting methodology

·         X-bar and R charts

·         P and C charts

 

2.      Process

·         Method

·         Establishing control limits

·         Calculating capability

 

Process

 

1.      Decisions

·         When and where? Proactive vs. Reactive

·         How to decide who should perform task

 

2.      How to use

·         Let the data guide your actions

 

Brass Tacks

 

1.      Do this for you, not the customer

·         Reduce waste

·         Control the process, do not let the process control you