by clicking the arrows at the side of the page, or by using the toolbar.
by clicking anywhere on the page.
by dragging the page around when zoomed in.
by clicking anywhere on the page when zoomed in.
web sites or send emails by clicking on hyperlinks.
Email this page to a friend
Search this issue
Index - jump to page or section
Archive - view past issues
button in toolbar for more information.
Metal Casting Technologies : September 2007
90 Back to the In this discussion the focus is on ensuring that honesty becomes a primary work ethic to ensure appropriate feedback, communication for safety and particularly to ensure productivity. Without honesty as being a core issue within the foundry, a domino affect can occur and the damage fallout can sometimes be too hard to fix. t might be said that old truths are always worthy of restatement and this is quite true about the foundry business. It is worthwhile to oversee how these truths are observed on the foundry floor because they could make a lot of difference in quality, productivity and, most importantly, reputation of the foundry. It will be seen that "honesty" is one of the most powerful words of the English language and is one of the most important ingredients in foundry operations. Honesty in the foundry business is meant to include both manufacturer and purchaser of castings, seller and customer -- because all of them form part of the foundry industry. THE PRODUCTION DEPARTMENT Taking as an example a fairly large foundry employing chemists, metallurgists and others; the smaller foundry will find its departments included in these. First there is the man who stamps the castings as to heat number or other markings. This entails accuracy, it is true, but still more, honesty. If the man's idea of a day's work is to do as little as possible, with as little care as possible, then he is not giving "an honest day's work." A mistake in the numbering of the castings would start a train of incorrect reasoning that would have costly results. There is another side to this, namely, where a Foreman might tell the man to mark the castings in a manner to deceive some individual, such as the inspector or other person. Such an act would have far-reaching results, but worst of all, it might turn an upright man into a cheat. Charge Preparation. There is the man who weighs out the various mixes of charges to the melting room. It is important here that such a man be trustworthy, that he follows the precept to "give full measure out, and weight with a right balance." The remark of the Foreman to such a one, "Be careful of the tin, but don't forget it's fifteen dollars a kilo," is not in any way building up the man's integrity. One cannot expect anyone to be dishonest upon suggestion and then revert to honesty for the rest of the day. Melting. Those whose duty it is to take the pouring temperature of the various metals before pouring have a job that depends for its usefulness entirely on faithfulness and accuracy. Immediately as the temperature is indicated by the pyrometer, time and cooling rate both come into play and all evidence is wiped out. The record must be made by one who is trustworthy for a really reliable record. The operation of melting the metal is an all-important one and we all know the significance of trifles such as charging solid metal first and borings later to the molten metal bath, or the loading of a crucible so that no metal sticks above it into the furnace atmosphere, or the removal of a high-zinc alloy as soon as the white flare of volatilized zinc oxide is noticed. All these things are by nature fugacious and therefore cannot to be checked by the occasional visit of the Foreman. The inherent honesty of the Melter is the Company's only protection. (Today, perhaps, the company can record what is happening at any point in the operation and store the same in a hard disk.) Molding. Moldmaking is still an art for the most part and therefore depends primarily on the individual's capacity, but whether this capacity is always used depends on the earnestness of the Molder, his interest in his work, his faithfulness to carry out the job to the best of his ability. A mold is closed and ready to pour. Were all the fillets properly made? Was the ramming too hard or too soft? Did the mold- halves fit exactly when closed, or was there any disturbance of the sand due to poor alignment? Did the pattern draw right or, if patching was needed, was it done well? The answers to all these questions depend on the man doing the work himself, and his honesty. (Again, today, high speed molding machines can overcome this problem when mass production is required; but the jobbing foundry should watch out.) Coremaking. The same applies to Coremakers -- a core might seem dry, but is it really? The man himself who made the core is the one who knows most about it. He might have hurried the drying, he might have said to himself: "Oh, that's good enough," and to his Foreman, "Yes, it's dry as a bone." The satisfactoriness of his cores depends, assuming that he knows his trade, on his trustworthiness. (This "good enough" attitude is a very serious defect of most foundry workers. There is a great need of developing quality consciousness in the workforce. Putting reliability of the work done on machines and the processes has done much towards the alleviation of this problem.) I (Based on Harold J. Roast, Cast Bronze; edited by Prof. J. H. D. Bautista, PMAI Consultant.) Honesty in the foundry business (PART 1) www.metals.rala.com.au