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Abstract

The scope of this work focuses on the aspects of quality and safety assurance of the iron cast manufacturing processes. Special attention

was given to the processes of quality control and after-machining of iron casts manufactured on automatic foundry lines. Due to low level

of automation and huge work intensity at this stage of the process, a model area was established which underwent reorganization

in accordance with the assumptions of the World Class Manufacturing (WCM). An analysis of work intensity was carried out and the costs

were divided in order to identify operations with no value added, particularly at individual manufacturing departments. Also an analysis

of ergonomics at work stations was carried out to eliminate activities that are uncomfortable and dangerous to the workers' health. Several

solutions were proposed in terms of rationalization of work organization at iron cast after-machining work stations. The proposed solutions

were assessed with the use of multi-criteria assessment tools and then the best variant was selected based on the assumed optimization

criteria. The summary of the obtained results reflects benefits from implementation of the proposed solutions.

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Authors and Affiliations

S. Kukla
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Abstract

The article presents the issues of costs analysis of iron casts manufacturing using automated foundry lines. Particular attention was paid to departmental costs, conversion costs and costs of in-plant transport. After the Pareto analysis had been carried out, it was possible to set the model area of the process and focus on improving activities related to finishing of a chosen group of casts. In order to eliminate losses, the activities realised in this domain were divided into activities with added value, activities with partially added value and activities without added value. To streamline the production flow, it was proposed to change the location of workstations related to grinding, control and machining of casts. Within the process of constant improvement of manufacturing processes, the aspect of work ergonomics at a workstation was taken into account. As a result of the undertaken actions, some activities without added value were eliminated, efficiency was increased and prime costs of manufacturing casts with regard to finishing treatment were lowered.

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Authors and Affiliations

S. Kukla
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Abstract

The paper presents the issue of production processes improvement in foundries in the area of finishing treatment of iron casts

manufactured on automated foundry lines with vertical or horizontal mould division. Due to numerous factors which influence

the efficiency of the processes, multi-criterion assessment tools were proposed in order to select the optimal solution for the assumed

criteria. After determining the criteria weight using the Saaty method, a simulation experiment was designed and carried out which

presents possible scenarios of casts finishing treatment operations. Basing on experiment reports from a computer model, particular

solutions were evaluated using the Yager’s method. The evaluation of the experiment results was performed by experts who assessed

different options according to each of the criteria adopted. After the establishment of the total standardized ratings by averaging the scores

given by individual experts, the final decision was generated. Using the presented method, the best solution was chosen from among

the analyzed scenarios.

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Authors and Affiliations

S. Kukla
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Abstract

The paper presents a practical example of improving quality and occupational safety on automated casting lines. Working conditions

on the line of box moulding with horizontal mould split were analysed due to low degree of automation at the stage of cores or filters

installation as well as spheroidizing mortar dosing. A simulation analysis was carried out, which was related to the grounds of introducing

an automatic mortar dispenser to the mould. To carry out the research, a simulation model of a line in universal Arena software

for modelling and simulation of manufacturing systems by Rockwell Software Inc. was created. A simulation experiment was carried out

on a model in order to determine basic parameters of the working system. Organization and working conditions in other sections of the line

were also analysed, paying particular attention to quality, ergonomics and occupational safety. Ergonomics analysis was carried out

on manual cores installation workplace and filters installation workplace, and changes to these workplaces were suggested in order

to eliminate actions being unnecessary and onerous for employees.

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Authors and Affiliations

S. Kukla
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Abstract

The article presents issues related to creating and realizing added value by logistic processes and processing in a casting enterprise. It discusses possibilities of improving systems of casts production by evaluating labour intensity of casts manufacture and analyzing manufacturing prime costs. Operations with added value, processes indirectly creating added value and operations without added value have been specified. The problem was presented on the example of materials flow design in a foundry, where casts are manufactured in expendable moulds and using automated foundry lines. On the basis of the Pareto analysis, a group of casts was specified whose manufacture significantly influences the functioning of the whole enterprise. Finishing treatment operations have been particularly underlined, as they are performed away from the line and are among the most labour-consuming processes during casts production.
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Authors and Affiliations

S. Kukla
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Abstract

The paper presents a practical example of improvement of foundry production systems in terms of post-finishing of nodular iron castings

produced in the conditions of bulk production for automotive industry. The attention was paid to high labour-intensive efforts, which

are difficult to be subjected to mechanization and automation. The times of actions related to grinding processing of castings in three

grinding positions connected with a belt conveyor were estimated with the use of a time study method. A bottleneck as well as limiting

factors were specified in a system. A number of improvements were proposed, aimed at improving work organization on the castings postfinishing

line. An analysis of work ergonomics at the workplace was made in order to eliminate unnecessary and onerous for the employee

actions. A model of production system using the Arena software, on which a simulation experiment was conducted, was drawn up in order

to visualize the analysed phenomena. The effects of the project were shown on graphs comparing times, costs, work ergonomics and

overall efficiency of production equipment indicator.

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Authors and Affiliations

S. Kukla

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