A detailed analysis of the overall time oriented processes involved in a foundry is called the process flow. The overall production in a foundry is termed as productivity. It must be mandatory to conduct a study on the productivity of a foundry for every annual term. Updating a process flow at regular intervals makes a huge impact on the entire productivity. This can be done by making a coherent process planning that involves studying every single aspect including the technical, manual and spatial factors.

1. Process flow for increased productivity in a foundry
A detailed analysis of the overall time oriented processes involved in a foundry is called the
process flow. The overall production in a foundry is termed as productivity. It must be
mandatory to conduct a study on the productivity of a foundry for every annual term. Updating
a process flow at regular intervals makes a huge impact on the entire productivity. This can be
done by making a coherent process planning that involves studying every single aspect
including the technical, manual and spatial factors.
Steps involved in a casting process:
1. Receiving the casting geometry:
The design is given by the customer. Either the blueprint is given or computer aided
designs are used to develop the drawings and given to the foundry along with the
quote.
2. Pattern making:
The pattern is made using pattern making sand. This is used to form the mold cavity into
which the metal is melted to be poured in.
3. Core making:
Core is formed by filling sand in to the mold cavity. Thus, there is a space between the
core and the mold into which the metal is poured to form the casting.
4. Mold preparation:
This is done by preparing the cavity in the mold by forming the pattern and then
withdrawing it to form the mold cavity so that the metal is poured in to set.
5. Melting and pouring:
After preparing the mold, the metal is melted in the furnace and then poured into the
mold cavity and allowed to be cooled. Melting is normally done in a separate place and
then transferred to the mold cavity. This could be done in the same premises to save
time.

2. 6. Cleaning and shakeout:
The set metal is taken out of the mold after it had cooled down and it is transferred to
the cleaning area of the foundry where all the impurities such as burnt sand and excess
metals are removed from the metal surface.
7. Inspection:
Finally, the product is checked for quality. Welding or machining is done if the product
needs more surface finish. It is inspected to be satisfying all the basic requirements as
well as any special demands given by the customer.
Each of these steps are affected by several factors such as,
1. Manual labor – both permanent and contract
2. Raw material availability
3. Space distribution
Casting geometry diagrams are drawn with the help of computer aided design software and are
sent along with the quotes through email. Though this is not time consuming, the problem
arises when there no manpower in the foundry to check if the design is fine or needs changes.
Again, there will not be a smooth process flow if there is a reduction in manpower to run the
shifts. As a result the machines go idle for a long time, which directly affects the productivity.
Proper utilization of manual labor is of utmost importance. Secondly, the availability of raw
materials must be constantly checked. Any insufficiency causes loss in production. The next
problem is improper or ineffective space utility. Each machine must be installed adjacent to
each other between regular intervals based upon the consequent processes to be done.
Scattering machines in a random manner results in the waste of time. Also, spreading machines
for a long a long distance or too much cluttering will again affect the process flow. Moving of
the materials back and forth wastes time. The shop floor must be able to equally accommodate
all the machines to carry out different processes. In some cases over processing and
overproduction can result in increased flow of scrap.
The study must be done based upon the following strategies.
1. Data study analysis
2. Effective plant layout
3. Feasibility study
4. Implementation of the new process flow

3. 1. Data study analysis:
A detailed process flow study is done by learning the layout of the foundry and
collecting all the data such as number of labor, both permanent and contract, number of
shifts run per day and number of working hours in a shift, available working time per
shift, allowed recess time, including lunch per shift, total working time per shift and per
day and everyday target production or number of pieces of finished product, based on
the customer’s demand per day. By calculating this, we can find out if the target is
reached or not. If not, it means any of these factors must be revised in order to
complete the target quantity per day.
2. Effective plant layout:
Space is an important factor that impacts the production. Uneven space distribution
consumes time, which in turn decreases or slows down the work that must be done to
reach the target quantity per day. If there are insufficiencies, then it must considered to
reorganize the machines in a sequential manner so that the material can be transferred
from one machine to the next based upon the orderly process that must be carried out
in a systematic manner. The raw material storage must be within the foundry and the
store must be kept ready with all the needed supplies all the time.
Any processes that are carried out manually must be upgraded to be done in an
automated method. This saves time and appropriate machines must be used in a careful
manner to handle raw materials in a safe way. For example, automated mold making
machines can be used instead of making mold by hand. This efficient way can guarantee
an increased production than the one resulted from manual labor.
A study must be carried out to know the other negative factors that are responsible for
unwanted machine failures and breaks resulting in machine idle time and a great
amount of backflow and scrap of materials. This will probably be as a result of incorrect
and inefficient handling of the machines. All the material handling equipments allocated
to handle raw material and finished products must be checked for effectiveness and
efficiency. All idle machines must be repaired to be ready for work. Unused and
unwanted machines that will not be required anymore must be definitely removed from
the shop floor premises, this way there will be sufficient room left to occupy the space
by installing new machines . Recruiting unskilled people for the means of cheap labor
can cause in equipment destruction. It is better to hire skilled labor or it will be

4. reasonable to organize for a training session to teach the inexperienced laborers to
handle the technical machines with care.
There must be proper communication in between the customer, the management and
the employees working on a different basis. Improper communication can result in
misunderstood or misinterpreted ideas that could mess with the planned processes. It is
also important to consider the expectations of the workforce on the shop floor. A
feedback session must be conducted to study from the reactions of the employees
about the daily or monthly wages they are provided. This will bring out if they are being
given the right wages that they actually deserve based upon all the regular market
strategies in offering salary to foundry employees. If there is dissatisfaction, then the
salary is to be revised so that this would trigger a desire for the employees to be more
positive towards their work.
3. Feasibility study:
After identifying the problems, suitable alternatives and alterations in the existing
process must be designed and proposed. This effective revised plant layout and revised
procedures must be given a feasibility study to ensure that it is going to work out for a
long term. Conducting discussions with all the people representing the management
and the employees will bring out ideas that could improve the new process flow to a
greater level. Here, concentration is done based on the future, not just for a few months
and for certain levels of the process but for a very long term aiming at high productivity
and high profits which means the employees will reap considerable rewards for their
efforts.
4. Implementation of the new process flow:
After conducting an effective cross analysis, the new process flow must be approved
and must be ready for implementation at a particular level. The budget required in
implementing these changes, including the plant layout with the shop floor, new
machineries, new workforce and other technical requirements must be evaluated with
accuracy. This will also include the cost that the foundry needs to spend in offering
revised wages for the employees. After evolving with all these requirements, the new
revised coherent process flow layout for an increased productivity in a foundry must be
implemented.

5. Finally, the one part that requires equal consideration is the delivery or shipping part of
the product. Each and every quote received must be agreed only after studying the
requirements of the customer. If the customer insists on doing additional inspection,
heat treatment, machining or other surface treatments for a smooth finish, then it must
be agreed upon based on the availability of time and labor in the foundry. Unfinished
products will not make a customer happy which will reduce the impression at the level
of clients. So, it must be understood and made clear to the person providing a quote
that you will or will not be able to meet out certain demands. If there is a mutual
agreement, then it must be kept until delivery of the product and it must be made sure
that the product reflects the effort that is being put to satisfy the customer.
Advantages of implementing the new coherent process planning:
1. Smart utilization of labor
2. Proper time management
3. Reduction of machine idle
4. Proper material handling
5. Structured communication between the employees
6. Timely delivery of products
7. Reaching targets per day
8. Improved overall finishing of the products
9. Improved customer satisfaction
10. Increased productivity
11. Increased overall profit
Implementing this process reduces backflow of the materials and reduces the scrap. Machine
idle time will also be reduced due to proper handling of equipments by skilled labor. This
process will definitely prove its capacity to alter the adverse situations in a foundry to improve
quality as well as quantity of the products. When customers get good quality at a price they can
afford, they are pleased to come forward with increased orders. This way the overall
productivity of the foundry increases, which also means better profit in the business.
VR Foundries is one of the best casting foundries in Coimbatore, India. The manufacturer
provides high quality SG & grey iron casting products for various industries such as
automobiles, pump manufacturers, textiles, hydraulics and more.