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.
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.