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.

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.