Small presentation as asked by an interviewer on - - Why FRP? - Describe the flow from generating an offer to certificate using Visio - Resource Planning - Description of Sand Moulding

2.  Reasons for the Indian foundry industry to use FRP
 Workflow from creating an offer to generating a certificate
 Resource planning
 Sand molding – Steps & Components
Points to be covered

3. According to the recent World Census of Castings by Modern Castings(USA), India
Ranks as 2nd largest casting producer in the world.
Casting production
worldwide in 2017 (in million
metric tons)
Status of the foundry industry in India

4. There are approx 5000 units in the country
that are engaged in various types of metal
castings.
Major foundry clusters are located in Batala,
Jalandhar, Ludhiana, Agra, Pune, Kolhapur,
Sholapur, Rajkot, Mumbai, Ahmadabad,
Belgaum, Coimbatore, Chennai, Hyderabad,
Howrah, Kolkata, Indore, Chennai, Faridabad,
Gurugram e.t.c.
90% of the units are classified as
MSMEs.
Foundry units in India

5. The Indian foundry industry manufacturers metal cast components for
applications in Automobiles, Railways, Power, Agriculture, Machine Tools, Valves
& Compressors, Electrical Equipments, Diesel Engines etc.
Sector-wise share of foundry

6. 10%
90%
Foundry Industry
Others
Internal
86%
Export
14%
Government’s Revenue – Mar19’ Cumulative share in Foundry Industry’s revenue
Foundry industry account’s for approx 10% of the total government revenue of India
as in 2019 that scales to cumulative value of 1584.85 INR Billion.
Out of the cumulative share, 14% i.e. 219.84 INR Billion accounts for the export part.
Share of foundry industry in India’s revenue

7. FRP will help in overcoming the current problems like . .
Order delays
Miscommunications, material tracking issue, WIP tracking issue, etc.
Coordination issue and quality issue between customers and suppliers.
Cost secrecy, material and energy inefficiency and process insecurity in real time.
Current issues faced by foundry industry

8. Structured resource plan for every foundry stage.
Saves time, material, money and increases productivity by providing bottleneck
management.
Reduces miscommunication due to less paper work for daily report and audit
preparation.
Single point of information – the same data for everyone on daily basis.
Standardized reports with tamper proof data provides correct information and
enables us to make decision at the right time based on valid data.
Collaborative work in a client server infrastructure with live updates in the systems.
No buck pass as work in real time is being recorded 24*7.
Online trace of each and every process in industry 24*7.
Production status, advance actions and alertness in real time helps in achieving
target on time.
Reasons to use FRP

9. • order to cert flow.pdf

10. Summarizes the level of resources needed to complete a project.
Schematic tree structure of all the prerequisite of 3M – Man, Machine and Material.
Provides a base for planning, costing and scheduling.
Includes hidden charges such as freight charges, job work charges, etc.
Resource Plan

11. Resource Plan - Schematic

12. FRP provides a unique way to plan resources in a layered form, starting
from purchasing to dispatching.
Every layer of the resource plan is a plan on its own, where each layer
describes different master data.
Resource Plan’s Schematic
Resource planning in FRP

13. Sand casting or sand molding, is a metal casting process characterized by using sand
as the mold material.
Over 60% of the metal castings are produced via sand casting process.
Benefits – Inexpensive, reusability, withstand extremely high temperatures.
Two sets of castings
(Bronze and Aluminum) from
the sand mold
Sand Molding

14. Steps involved in sand molding prior to the cooling of casting –
Mold – Making:
 First process is to create the mold for the casting. Sand mold is formed by packing
sand into each half of the mold. The sand is packed around the pattern, which is a
replica of the external shape of the casting. When the pattern is removed, the
cavity that will form the casting remains. Any internal features of the casting that
cannot be formed by the pattern are formed by separate cores which are made of
sand prior to the formation of the mold.
Cope & Drag (top and
bottom halves of a sand
mold), with cores in
place on the drag
Sand Molding - Steps

15. Pouring:
 The molten metal is maintained at a set temperature in a furnace. After the mold
has been clamped, the molten metal can be ladled from its holding container in
the furnace and poured into the mold. The pouring can be performed manually or
by an automated machine. Enough molten metal must be poured to fill the entire
cavity and all channels in the mold. The filling time is very short in order to
prevent early solidification of any one part of the metal.
Molten metal in Sand Mold
Status of the Foundry Industry in India

16. Clamping :
 Once the mold has been made, it must be prepared for the molten metal to be
poured. The surface of the mold cavity is first lubricated to facilitate the removal of
the casting. Then, the cores are positioned and the mold halves are closed and
securely clamped together. It is essential that the mold halves remain securely
closed to prevent the loss of any material.
A closed Sand Mold
Sand Molding - Steps

17. Pattern:
 A skilled pattern maker builds the pattern of the object to be produced, using wood, metal
or plastic such as expanded polystyrene.
 Pattern is usually slightly larger than the finished product and the difference is known as
contraction allowance.
 Patterns have core prints that create registers within the molds into which sand cores are
placed.
Sand:
 To create the mold, silica sand (SiO2) is used which is mixed with a type of binder to help
maintain the shape of the mold cavity.
 Unique types of sand molds – Greensand mold, Skin-dried mold, Dry Sand mold, No-
bake mold.
Sand Molding - Components

18. Tools:
 A multi-part molding box, the top and bottom halves of which are known
respectively as the cope and drag, is prepared to receive the pattern.
 Cores are required to create the castings with holes and can be made up of
refractory materials.
 Chaplets are the supports for the cores that are needed particularly when cores
are very big.
 Chills are the metal plates that are placed to control the solidification structure of
the metal.
Sand Molding - Components