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Conference focuses on foundry industry future.

With the theme, "Foundries in the Year 2000--Where Will You Be?" nearly 200 foundry officials gathered at the 42nd Annual AFS Northwest Regional Conference February 19-20 in Portland, Oregon, to hear what's ahead in the industry.

A total of 14 technical speakers presented their thoughts on what impact the economy, regulations, alternative technologies and ISO 9000 will have on the industry in the next 10 years.

ISO 9000

Jerry Mills, corporate manager, quality assurance, ESCO Corp., cleared up some common confusion in his presentation on implementing ISO 9000 into foundries. He said it's a certification of a system--not products--and noted that 9004 is not a standard but guidelines for quality management; 9001 concentrates on design and development; 9002 is manufacturing and production; and 9003 deals with testing and inspection.

Mills recommended training everyone, developing documents at every operating level, developing a strong internal audit program, allowing systems to develop objective evidence, selecting registrants early, using electronic data whenever possible, designing prior to development and paying for a preassessment audit.

"If you don't document it, it didn't happen," he said, summing up how to meet the standard. "If it doesn't move, calibrate it. If it does move, train it."

Environmental Philosophy

Jeffrey Ring, attorney with Heller, Ehrman, White & McAuliffe, spoke on changing environmental regulations and inspections of industrial facilities.

He noted that the major buffer for industry disappeared when President Clinton abolished former Vice President Quayle's Council on Competitiveness. The elimination of this council will result in an increase in rulemaking, and will prove to be significant to enforcement and criminal prosecuting.

Ring said 1993 is already being dubbed the year of EPA and the year of RCRA. He said the coming year will show promulgation for corrective action and a revised definition of waste. Some 5500 waste sites will be addressed.

He also said there's a distinct change in enforcement strategies, and officials will be coming out "gung ho." Of all EPA personnel, 20% are dedicated to enforcement and that number is expected to increase. In 1992, a record was set for felony indictments--with a conviction rate of 95%.

Ring also spoke on the Environmental Crimes Bill, which focuses on knowing endangerment. The doctrine of ultimate responsibility has a consequential effect on corporate managers, he said. "They're going to be free to go after managers, not corporations," he concluded.

Technology for Clean Air Act

Included in "Positioning Your Foundry for the Clean Air Act Amendments of 1990," a presentation by James Rickum, RMT, Inc., was a session on Title III hazardous air pollutants. He said maximum available control technology (MACT), around which Title III revolves, is the maximum degree of reduction achievable in terms of cost, energy requirements and other nonair quality health environmental impacts.

New sources are as stringent as achieved in practice by best controlled similar sources, and existing sources are the average of the top 12% of existing sources.

MACT involves the techniques, methods, or systems that:

* reduce emissions through process changes;

* enclose systems to eliminate emissions;

* collect, capture or treat from process stacks, vents and fugitive sources;

* provide design, equipment, work practice or operational standards (operator training/certification).

Targeting furnace operations, core/mold binder chemicals, pouring and cooling, shakeout, finishing operations and sand reclamation, the schedule for MACT for iron and steel foundries is 1997--MACT promulgated; 2000--compliance with no extension; and 2001--compliance with extension.

Blastcleaning Tips

Dennis Denyer, Pan Abrasives, talked about blastcleaning in his presentation, "Stick to the Basics--Now and into the 21st Century."

He said foundries should always use the smallest size abrasives needed for impact. The larger the shot, the rougher surface profile and deeper the layer of impingement. Shot 570 is the smallest and provides 800X coverage, while the largest size, 5780, provides 1.6X impact value.

Denyer said the key to efficient blastcleaning is controlling your work mix. He also stressed getting your machinery free of leaks, eliminating the carry-out of abrasives, making frequent additions of relatively small amounts, obtaining optimum air flow and adjusting baffle plates in the separator to assure full curtain of air.
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Title Annotation:1993 AFS Northwest Regional Conference
Author:Kanicki, David P.
Publication:Modern Casting
Date:Apr 1, 1993
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