Aiming for lean manufacturing. (Engineering).

In the nine papers and panels sponsored by the Engineering Div., speakers concentrated on promoting lean manufacturing.

The panel "Man vs. Machine" (02-184) featured presentations by B. Townsend, Barrett Technology, Inc., T. Lockert, Electric Controls & Systems, G. Dalgaard, Grede Foundries, Inc., and E. Erlbacher, PushCorp, Inc.

Lockert offered an overview of the types of robots available to today's foundries, as well as potential foundry applications (core placement, gate and riser removal, grinding/finishing, and sorting and gauging). He also discussed the placement of robots, explaining that they must be integrated into the manufacturing process and protected.

Robots require protection from the environment, other machines and people. They also must be set up in a manner that protects those working nearby. Lockert reminded attendees that "effective automation makes complex technology operate with apparent simplicity."

Erlbacher explained the difference between choosing force or position in end-arm tooling for robots. Force occurs when the robot tooling maintains consistent contact and level of force with the part, following contours and providing a more human-like touch. Positioning tooling has no flexibility--it goes to the same spot each time and produces the same action regardless of whether or not it comes in contact with a part. Another choice to be made in robotics is whether the part comes to the media (robot) or the media comes to the part. Small or complex castings can be brought to the robot more easily, and can combine with loading and unloading operations. The media generally travels to the part when passive or active force tools are used and castings are larger.

Stating that "the foundry is a natural location for automation," Dalgaard provided financial justification for implementing robotics. He divided savings into three categories--

Cost savings:

* cycle time and personnel reduction;

* fewer delays because of more consistent output;

* reduced scrap returns;

* support equipment reduction.

Cost avoidance:

* safety concerns (insurance, direct medical costs from injuries);

* employee turnover on tedious jobs leading to retraining;

* building and equipment (robotics often fit in a smaller space than the same operations performed manually).

Intangible savings:

* improved casting quality and appearance;

* content employees because of reduced manual labor;

* increased workflow and inventory control (less material handling--material that moves, moves faster);

* a cleaner work environment.

Beyond using robots to make manufacturing leaner, other areas of the foundry can benefit from lean thinking. In the "Lean Approaches to Quality" (02-174) panel, T.C. Wilson, Hickman Williams & Co., T.J. Schorn, Enkei America, Inc., and S. Ebert, Waupaca Foundry, spoke on documentation, problem solving and costs, respectively.

Williams explained that the costs of over-documenting are huge because of all of the paper, filing and manpower required. Rather than working with bloated manuals that are so detailed they're virtually useless, companies should aim for the lean approach--a clear, concise guide. Other keys to lean documentation include:

* interview contributing parties and summarize their instructions;

* provide definitions only if necessary;

* don't document every exception--just provide the basics and let managers manage;

* use high-impact lean documents such as charts, photos and samples.

Schorn questioned why inspection is necessary, citing quality control processes as the means for eliminating defects. He stated that a quality control program reduces the need for inspection because it catches casting flaws earlier in the process. He reminded that quality cannot be "inspected in," that it needs to be designed into the parts from the beginning.

Inspection most often is focused at the end of the production line, but it should occur early in the process at the point where it costs the least money to remove errors or defects, he said. Schorn said that if foundries must inspect, they should use strategic sampling inspection rather than 100% inspection because it's more effective and efficient.

Also presented by the AFS Engineering Div. were papers on modeling sand core blowing and computer simulation for various methods of green sand filling.