Productivity Improvement of Non Ferrous Foundry

A Project Report
Submitted by

VATSAL DOSHI
JINAL LAD
MOHAK MEHTA
PALASH SRIVASTAVA
Under The Guidance Of
Prof.B.J DESAI
in partial fulfilment for the award of the degree
Of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

at
MUKESH PATEL SCHOOL OF TECHONOLOGY MANAGEMENT AND
ENGINEERING,
SVKMs NMIMS UNIVERSITY, MUMBAI
APRIL 2016

CERTIFICATE

This is to certify that the project entitled Productivity Improvement of Non Ferrous Foundry is
the bonafide work carried out by VatsalDoshi, Jinal Lad, Mohak Mehta, Palash Srivastava of
B.Tech(Mechanical Engineering), MPSTME (NMIMS), Mumbai, during the VIII semester of the
academic year 2015-2016, in partial fulfilment of the requirements for the award of the Degree of
Bachelors of Engineering as per the norms prescribed by NMIMS. The project work has been
assessed and found to be satisfactory.

Prof. B.J Desai

Internal Mentor

Examiner 1

Examiner 2

Dean
Dr.S.Y.Mhaiskar

DECLARATION

We, Vatsal Doshi, Jinal Lad, Mohak Mehta, Palash Srivastava Roll No. F011, F021, F023,
F049 of B.Tech (Mechanical Engineering), VII semester understands that plagiarism is defined as
anyone or combination of the following:
1. Un-credited verbatim copying of individual sentences, paragraphs or illustration (such as
graphs, diagrams, etc.) from any source, published or unpublished, including the internet.
2. Un-credited improper paraphrasing of pages paragraphs (changing a few words phrases, or
rearranging the original sentence order)
3. Credited verbatim copying of a major portion of a paper (or thesis chapter) without clear
delineation of who did wrote what. (Source: IEEE, The institute, Dec. 2004)
4. I have made sure that all the ideas, expressions, graphs, diagrams, etc., that are not a result of
my work, are properly credited. Long phrases or sentences that had to be used verbatim from
published literature have been clearly identified using quotation marks.
5. I affirm that no portion of my work can be considered as plagiarism and I take full responsibility
if such a complaint occurs. I understand fully well that the guide of the seminar/ project report may
not be in a position to check for the possibility of such incidences of plagiarism in this body of
work.

Signature of the Student:

Name: Vatsal Doshi, Jinal Lad, Mohak Mehta, Palash Srivastava
RollNo.F011, F021, F023, F049
Place: Mumbai
Date: 21 April 2016

ACKNOWLEDGEMENT

Its our pleasure to thank our Dean Dr.Shrad Y. Mhaiskar for his encouragement and support.
His positive approach has always been a guiding spirit for all our research and development.
We wish to express our sincere gratitude to our project guide Prof. B J Desai for his guidance,
encouragement and support throughout our project. We must thank him for guidance and utmost
attention on various journal and presentations. His constant evaluation on our project and
collaboration of apt solutions has helped us to conclude with innovative ideas and results.

We would also like to thank the owner of the Non Ferrous Foundry Mr.Kishor Mehta for his
constant support, technical guidance, acceptance and patience for our professional requirement.

Abstract

The casting process was probably discovered around 3500 BC in Mesopotamia. Since then
humans have been using this process in various areas. With passage of time many new
technology have come up in casting. It todays world with fast growing technology, variety of
customer needs and competition in market, it is not only important to provide quality but also get
work done in minimum time.

We choose this project to enhance our as well as improve their management skills. This project
will help solve industry manufacturing problems, analyse method and time study so as to
improve it, improve production cycle, enhance casting manufacturing quality and ergonomics
and safety of workers.

The companys current customer relations are strong not due to its quality of work but solely due
to old business relations. We want quality to become the prime factor for business relations. So
achieving good quality product and in minimum time is the need of the hour for this company to
keep up with ever increasing market competition. The company likes to run the old traditional
way and hence pays less attention on the management and safety of its workers.

Table of Contents
List of Tables...............................................................................................................................1
List of Figures.............................................................................................................................2
Abbreviations...4
1. Introduction ...5
1.1 About Non Ferrous Foundry..5
1.2 Products of NFF.5
2. Casting Processes....6
2.1 About Casting .....6
2.2 Process Flow chart7
2.3 Melting Process.8
2.3.1 Furnace used in NFF Cupola..8
2.4 Sand Processing.9
2.4.1 Green Sand Moulding.9
2.4.2 Batch-Type Muller10
2.5 Pattern..11
2.5.1 Type of Pattern.11
2.5.2 Pattern Handling and Storage...11
2.6 Mould making Process (ASM).12
3. Study and Analysis.14
3.1 Scope of Study14
3.2 Work Study.15
3.2.1 Procedure..15
3.3 Flow Process Chart..17
3.4 Ramming Process.19
3.4.1 Definition..19
3.4.2 Current Practice19
3.4.3 Pneumatic Rammer...21
3.4.4 Cost Estimations...22

3.5 Removing Pattern from Mould22

3.5.1 About Process22
3.5.2 Current Technique.22
3.5.3 Proposed Technique..23
3.5.4 Advantages of Proposed Technique..23
3.5.5 Alternate Proposal Suggested23
3.6 Supplying Sand to Moulder24
3.6.1 About Process24
3.6.2 Need for Optimization..25
3.6.3 Suggestion26
3.7 New Mould Box..28
3.7.1 Function of Mould Box28
3.7.2 Reasons to use New Mould Box28
3.7.3 Features of New Mould Box...29
3.8 Mould Box Storage30
3.9 Moulding Area..31
3.9.1 Benefits of New Moulding Area32
3.9.2 Features ofNew Moulding Area32
3.10 Plant Layouts..34
4. Evaluations and Calculations.37
4.1 Ramming Calculations 37
4.2 Evaluation of removing Pattern from Mould.38
4.3 Calculations of Supplying Sand to Moulder .38
4.3.1 Reduction of material and workers movement.38
4.3.2 Increasing Container Capacity...38
4.4Calculationsof New Mould Box ...39
4.5 Evaluation of Mould Box Storage Area 40
4.6 New Moulding Area..40
4.6.1 Dimensions of New Work Bench and Conveyor40
4.7 New Plant Layout..40
5. Summary..41
5.1 Summary Table.41

List of Tables

CHAPTER
1.
2.
3.
4.

TITLE
INTRODUCTION
CASTING PROCESS
STUDY AND ANALYSIS
EVALUATION AND CALCULATION
Table4.1: Comparison of hand rammer

PAGE NO.

& pneumatic rammer.

Table4.2: Reduction of material & worker's
Movement
Table4.3: Effects due to container change
Table4.4: Cost Saving calculation due to use of
proposed mould box
Table4.5: Yearly salary calculation of worker
Table4.6: Final Result

List of Figures
PAGE NO.

CHAPTE
R
1.
2.

TITLE
INTRODUCTION
CASTING PROCESS
Fig2.1: Pouring in Casting
Fig2.2: Solidification in casting
Fig2.3: Flow Process Chart
Fig2.4: Cupola Furnace in NFF
Fig2.5: Sand Flow Chart
Fig2.6: Sand Churner in NFF
Fig2.7: Components of a conventional vertical
batch type Muller
Fig2.8: Loose Pattern of an IC Engine Casing
Fig2.9: Storing of Pump body Pattern in NFF
Fig2.10: Green Sand mould in NFF
Fig2.11: Basic Steps involved in making a casting
from a green sand mould

3.

STUDY AND ANALYSIS

Fig3.1: Work Study Procedure (ILO)
Fig3.2:Flow Process Chart (Source ILO)
Fig3.3: Self-made Flow process Chart
Fig3.4:Manual Ramming Process at NFF
Fig3.5: Earth Rammer on Weighing Machine
Fig3.6: Pneumatic Rammer
Fig3.7: Pneumatic Rammer during Operation
Fig3.8: Skilful Removal of pattern from mould
Fig3.9: CAD Model of L-Tool
Fig3.10: Removal of Pattern using L-tool
Fig3.11: Aluminium Suction Cup
Fig3.12: Helper filling sand
Fig3.13: Helper Transporting sand container
Fig3.14: Suggested Container
Fig3.15: Container with sand
Fig3.16: Sand Container on weighing Machine
Fig3.17: Gravity Roller Conveyor Bench
Fig3.18: Current Moulding box
Fig3.19: Melt leakage due to deformation and
dis-alignment of mould box pair
Fig3.20: Corroded mould box
6

Fig3.21:Sample of proposed Mould box

Fig3.22: Stacking of Mould boxes
Fig3.23: CAD model of Mould boxes on hanger
Fig3.24: Current Position of moulder while moulding
Fig3.25: Position of moulder working on Roller Workbench
Fig3.26: Sketch Layout of Moulding Area
Fig3.27: Current Plant layout
Fig3.28: New Plant Layout

ABBREVIATION

NFF

Non Ferrous Foundry

ASM

American Society of Materials

ILO

International Labour Organization

CI

Cast Iron

Chapter: 1
Introduction
1.1 About Non Ferrous Foundry
NFF is a casting manufacturing company founded by Shree Dheerajlal Mehta in the year 1970.
Currently under Kishor Mehta since 2001. The foundry is located in Vapi, Gujarat. It
manufactures majorly CI, Aluminium, Bronze, Gun metal castings. Casting products include
motor cover, pump body, pulley, fire bar, type of bushes, rods, circles, square blocks and other
customized machinery parts. Field of business is around Vapi in Daman, Umargaon, Silvassa,
Dadra Nagar Haveli. There are about 10-15 workers working in the company.

1.2 Products of NFF:

1. V-Belt Pulley
2. Impeller
1

3. Pump Body
4. Plate type Pulley
5. Motor Cover
6. Fire Bar
7. Sewage Cover
8. Ingot
9. Other general purpose products like Bush, Rod,
Circle, Square block, CI Hand wheel, Ring.

Chapter 2
Casting Processes

2.1 About Casting

Casting is a manufacturing process in which molten metal is poured or injected and allowed to solidify in
a suitably shaped mould cavity. During or after cooling, the cast part is removed from the mould and then
processed for delivery. Casting processes and cast -material technologies vary from simple to highly
complex. Material and process selection depends on the part's complexity and function, the product's
quality specifications, and the projected cost level.Castings are parts that are made close to their final
dimensions by a casting process. With a history dating back 6000 years, the various casting processes are
in a state of continuous refinement and evolutions technological advances are being made.

Fig.2.1 Pouring in casting Fig 2.2 Solidification in casting

2.2 Flow process chart

Fig 2.3 Flow process chart

2.3 Melting
4

2.3.1 Furnace used in NFF- Cupola

The cupola is basically a cylindrical shaft furnace that burns coke intensified by the blowing of air
through nozzles. Alternate layers of metal, along with replacement coke, are charged into the top. In its
descent, the metal is melted by direct contact with the countercurrent flow of hot gases from the coke
combustion. The molten metal collects inthe well, where it is discharged for use by intermittent tapping or
by continuous flow
In high-tonnage operations, the cupola remains the most reliable source of the continuous high volumes
of iron needed to satisfy multiple moulding lines of high-production foundries or multiple casting
machines of centrifugal pipe producers. The continuous stream of cupola-melted iron is not interrupted by
charging, which is done independently upstairs on theback side, nor by slag removal, because the slag
flows off to the side continuously from front or rear slag spout without interrupting the melting.

Fig. 2.4Cupola furnace in NFF

2.4 Sand Processing

5

2.4.1 Green Sand Moulding

Fig 2.5Sand flow chart

It is one of many methods available to the foundry man for making a mould into which molten metal can
be poured. Green sand moulding and chemically bonded sand moulding are considered to be the most
basic andwidely used mould making processes. Green sand media are prepared by coating the grains of
sand with binder that is later shaped into a rigid mass by the application of force. Green sand moulding is
the least expensive, fastest, and most common of all the currently available moulding methods. The
mixture of sand and binder can be used immediately after the mixing process that coats the sand grains.

2.4.2 Batch-Type Muller

6

Although not a new design, the batch-type Muller can produce high-quality mouldingsand. It is equipped
with plows to move the sand mass under the large, weighted rolling wheels, which are verticallyoriented.
This kneading action provides the capability of consistent control but not short cycle times.

Fig 2.6 Sand churner in NFF

Fig. 2.7Components of a conventional vertical wheel batch-type Muller

2.5 Pattern
7

2.5.1 Type of Pattern

Loose patterns, also called one-piece patterns or solid patterns, are the simplest, least expensive type of
reusablepattern and are suited only to very low-quantity production. This type of pattern is most
appropriate for experimental or prototype castings and is only rarely used for short-run production
castings. Moulding with a loose pattern requires more manual operations and a much higher degree of
moulder skill than moulding with other pattern types. Manyfoundrymoulding departments are not set up
to use loose patterns. This increases the cost per mould and results in variations in casting quality from
mould to mould compared to mouldmaking with other pattern types. A loose pattern can be made in one
piece or in two pieces (split patterns). The split in the two-piece pattern corresponds to the parting line in
thepattern. One-piece loose patterns are often used when one side of the pattern is a flat plane that can
serve as the parting line, while two-piece loose patterns are more commonly used when the shape to be
cast is more complex.Moulding with one-piece loose patterns often requires considerable time and skill
on the part of the moulder

.
Fig 2.8 Loose pattern of an IC engine casing

2.5.2 Pattern Handling and Storage

Because significant investments are made in pattern equipment, pattern handling and storage must be
carefully considered by the foundry. Improper storage and handling can cause pattern deterioration and
damage, particularly for wood patterns because humidity and temperature changes can cause severe
distortion. The foundry typically has many patterns in inventory. Obsolete or discontinued patterns should
be routinely destroyed to make room for new patterns.

Fig 2.9 Storing of pump body pattern in NFF

2.6 Mould Making Process (ASM)

The sequence begins with a mechanical drawing of the desired part. Patterns are then produced and
mounted on pattern plates. Both the cope and drag patterns include core prints, which will produce
cavities in the mould to accommodate extensions on either end of the core. These extensions fit solidly
into the core prints to hold the core in place during pouring. The gate or passageway in the sand mould
through which the molten metal will enter the mould cavity is usually mounted on the drag pattern plate.
Locating pins on either end of the pattern plates allow for accurately setting the flask over the plate. Cores
are produced separately by a variety of methods. The core boxes, which are rammed with a mixture of
sand and core binder. If the cores must be assembled from separately made components, they are pasted
together after curing. They are then ready to be inserted into the sand mould. The mould is made by
placing a flask (an open metal box) over the cope pattern plate. Before moulding can begin, risers are
added to the pattern at predetermined points to control solidification and supply liquid metal to the casting
to compensate for the shrinkage that takes place during cooling andsolidification. Thus, any shrinkage
voids form in the risers, and the casting will be sound. A hole or holes (called sprues) must also be formed
in the cope section of the mould to provide achannel through which the molten metal can enter the gating
system and the mould cavity.
The cope half of the mould is produced by ramming sand into the flask, which is located on the pattern
plate with pins. The flask full of sand is then drawn away from the pattern board, and the riser and sprue
pieces removed. A flask is subsequently placed over the drag pattern plate using the locating pins on the
plate. Sand is rammed around the pattern, and a bottom board is placed on top of the flask full of sand.
The pattern, flask, and bottom board are then rolled over 180, and the pattern is withdrawn. The
9

completed core is set into the core prints in the drag half of the mould and the cope half of the mould is
set on top of the drag. Proper alignment of the mould cavity in the cope and drag portions of the mould is
ensured by the use of closing pins, which align the two flasks. The flasks can be clamped together, or
weights can be placed on top of the cope, to counteract the buoyant force of the liquid metal, which would
otherwise tend to float the cope off the drag during pouting. Metal is then poured into the mould cavity
through the sprue and allowed to solidify. The casting is shaken from the sand and appears, with the
sprue, gating system, and risers attached. Following shakeout, the flasks, bottom boards, and clamps are
cycled back to the moulding station while the casting is moved through the production process. When the
gates and risers are removed from the casting, they are returned to the furnace to be re-melted. After
cleaning, finishing, and heat treating, the castings are ready for shipment.

Fig 2.10 Green sand moulds in NFF

10

Fig 2.11Basic steps involved in making a casting from a green sand mould

11

Chapter 3
Study and Analysis
3.1Scope of Study
In our Study, we used 20-80 rule which states that 80% of the effects or problems come from 20% of the
causes. So we focused on the most crucial process of casting where a minor improvement can cause a
major change .The Process is Moulding
During the study, we focused on the factors affecting the productivity related to moulding process which is
the scope of our study.
We do not intend to change the process/operations followed by the company since 45 years to produce their
quality casting but we intend to study, analyse and suggest a different way of doing the same
process/operation in order to produce optimized output.

12

3.2 Work study

It is the systematic examination of the methods of carrying on activities so as to improve the effective use
of resources and to set up standards of performance for the activities being carried out.

3.2.1 Procedure:

Fig 3.1 Work Study Procedure [k]

13

a) Select:
For studying moulding process, we classified job to be studied in 3 categories that is small, medium and
large size castings .In the plant generally for every 10 casting jobs, 7 are small sized casting,2 are medium
sized and 1 is large sized casting as been informed by Plant manager of the company.
So we selected 6 random small size casting, one medium size casting and one large sized casting as our
subject to study moulding process
b) Record:
Flow Process Chart was made and used in order to record time taken and distance travelled by worker in
completing a process
Tools for recording data used were stop watch and measuring tape .The readings were jotted down
simultaneously onto the chart while the worker was performing the operation of moulding of jobs under
study.
c) Examine:
Examination of each and every process was done carefully taking in account of the time and effort being
put up and also loss/wastage of material being done during the act.
We focused on few processes where effort made and time consumed can be reduced
From the observation we found that with a little remedial action or a little modification here and there in
few of the processes a drastic reduction in material handling, time consumption and wastage of material
could be achieved.
d) Develop:
We tried to develop this by taking in to reference few companies like Panchal foundry,
We even took suggestion from workers who are working in the industry
We took ideas about the way the processes were performed from a company named Spring City Electrical
Manufacturing Foundry[o] which exports their products in international market through YouTube videos.
We used ASM handbook for referring standards of process and techniques followed in casting.
e) Evaluation and Definition:
14

The results which we have obtained and the new methods which we have suggested are explained in
detail in next chapter.

3.3 Flow Process Chart

Fig 3.2 Flow process chart [p]

15

Fig 3.3 Self-made process chart

Its features are: Table can help Analyst to record time as well as distance in proper order for the Event
where it is necessary.
We can classify the events using symbols which includes symbol OPERATION,
INSPECTION,COMBINE,TRANSPORT,DELAY,STORAGE.Also the flow can be analysed by joining
the type of event by its order of flow.
Analyst can also recommend methods if they find it as a totally incorrect method.
This table can be used as FLOW PROCESS CHART for WORKER TYPE, MATERIAL TYPE, and
MACHINETYPE. Analyst can use both for Recording Present Event Study as well as proposing the data.
So that the analyst can effectively analyse the study comparing both charts simultaneously.
Also a REMARKS space is given in the table for the analyst to record those things which is to be taken in
consideration while analysing and is not directly related to Events of the process.
Table provides space for Adding notes and proposing estimated saving from the proposed methods.
16

3.4 Ramming Process

3.4.1 Definition[a]
This is a process in which striking of the moulding sand mass is done in the moulding box to pack
uniformly around the pattern. The common forms of rammers used in ramming are hand rammer, peen
rammer, floor rammer and pneumatic rammer.

3.4.2 Current Practice

Manual Ramming is heavy and difficult to use. A lot of energy and time is involved with average
performance. The heavy hammer damages the mould boxes with several inaccurate blows. On-uniform
load distribution and compression on sand leads to poor quality of mould. Also the efficiency of the
worker decreases over time with manual ramming
Currently the process is done completely manually.

Using Hand Rammer and Earth Rammer

Worker pressing the sand by his own body weight

Fig 3.4 Manual ramming process at NFF

17

Earth Rammer weight around 5.4kgs requires effort to lift and drop continuously. Good Physical strength
is required.

Fig 3.5 Earth rammer on weighing machine

Beats to the sand to settle in the mould using hand rammer is done manually causing arm pain and back
pain due to its working position on a long run. Efficiency of worker decreases on a longer run.

3.4.3 Pneumatic Rammer

Pneumatic rammer uses compressed air for delivering fast blows with the help of reciprocating piston for
ramming sand. It saves a lot of workers energy and time. It doesnt damage the mould boxes while
ramming.

18

Fig 3.6 Pneumatic rammer

Fig 3.7 Pneumatic rammer during operation

3.4.4 Cost Estimations [d]

Costs: Steel Pneumatic Rammer: Rs12, 500 + Delivery charges
Compressor and Tank: Rs 6,006 +Delivery Charges
Attachment cost: Rs 600
Total: Rs 19,006

3.5 Removing Pattern from Mould

3.5.1About Process
In this process the pattern which is embedded in the moulding sand is to be drawn out from the mould
cavity. This process should be done carefully with skill because if proper care is not taken then cavity
dimension will change.

3.5.2Current Technique
Currently the worker insert pins on top surface of pattern and tightens a steel wire around pins in order to
lift up the pattern.
19

This method to remove pattern requires skill of tightening the wire around pins as well as deciding the
points to be inserted into pattern to maintain balance while lifting the pattern.

If the pattern is to be re-used then pins has to be inserted again but at different pointwhich causes damage
to the pattern on longer run.
Another method used was striking the pattern with a wooden hand rammer lightly to loosen up the pattern
from the moulding sand in contact, and then pulling up the pattern skilfully with hand
In both the above mention methods, the cavity of mould is prone to damage which causes change in
dimension of the final casting if the lifting of pattern is not done slowly with skill and patience

Fig 3.8 Skilful removal of pattern from mould[e]

3.5.3 Proposed Technique

Use L-tool as shown in figure having a sharp point at one of its end. It has screw treads on that end to
engage with wooden pattern for its withdrawal from the mould.

20

3.5.4 Advantages of Proposed Technique

Eliminates the repetitive action of inserting nails/pins in pattern thus reducing pattern damage.

It is very easy to use .Just screw the tool in pre-screwed point into pattern and pull it.

This technique speeds up the work of removing pattern compared with current practice.

Skill isnt required to do the above task using L-tool.

During batch production of any casting. The Pattern has to be used multiple times. In such cases
this method serves as an ideal way of removing pattern from mould as the pre-screwed point can
used several times to remove it.

The proposed method reduces mould damage while lifting the pattern unlike currently used
techniques.

Fig 3.9 Cad model of L tool

Fig 3.10 Removal of pattern using L tool[4]

21

3.5.5Alternate proposal suggested [eba]

Tool Name: Suction Dent Puller
Specification:
Diameter: 4-1/2" Capacity: 110 LB
Application: Perfect for Door Dings, Great for Lifting Heavy/Bulky Objects (Windows, Mirrors, Doors,
etc.)
Maximum lifting capacity 50kg
Price = Rupees 765

Fig 3.11 Aluminium suction cup

Working:
Create and release suction between contact surfaces with help of two given handles. Once the suction is
built between cup and pattern surface, then with the help of the handle, the pattern is pulled out.
Features of suction cup:

Long lasting due to robust design.

22

Corrosion resistant because of aluminium body

Easy to use as skill isnt required much compared to above mentioned techniques

Doesnt damage mould cavity while lifting pattern.

High lifting capacity up to 50kg

Doesnt require any tampering with pattern.

Limitations of suction cup:

The surface has to be free from any sand particles and cleaned before using the suction cup

The geometry of the pattern should be such that inner surface of the cup should not be exposed to
air when the cup is pressed onto pattern surface with the help of the handle .This will create proper
suction between contact surface.

3.6 Supplying Sand to Moulder

3.6.1 About Process:
During moulding process, moulder requires green sand every now and then for filling up the mould box
tightly so pattern fixes up firmly which prints the shape of cavity with close dimension. With the currently
used container for holding green sand the worker needs minimum three to four container full of sand for
filling up small mould box .Likewise 6-7 container of green sand to fill up medium size mould box.
The supply of sand tomoulder is done by Helper or if helper is indulge in some work then moulder has to
fill the sand container by himself and take it back to moulding spot.
Each container of sand weighs around 14.5kg and contains 5.5 litres of green sand in volume.

23

These sand filled containers are filled and carried by helper/moulder (as shown in fig) and then
transported from sand churner to moulding spot.

Fig 3.12 Helper filling the container

Fig 3.13 Helper transporting the sand container

3.6.2 Need for Optimization:

In the process/operation of supplying sand, drawback seen is that helper/moulder has to carry container
right from sand churner till moulding area manually .Moreover minimum 3 rounds of supply are needed
with use of such container. The round of supply increases with increase in size of mould box used for
moulding.
The moulding point is not fixed but it keeps on changing as placement of moulds is done one by one.
Since moulding point is not fixed, so will be the moving path of moulder where it may sometime occur
that moulder finds difficulty in passing carefully across ready-to-pour moulds in plant. This adds to time
spent on completing the whole process.
Rounds of supply can be reduced by supplying more sand at once compared to currently used container.
So there was a need for optimization process by fixing the above issues.
24

3.6.3 Suggestion
We suggest them to use a different container which carries more volume of green sand so as to decrease
the frequency of supply. Also to limit the distance of material and worker movement a specified path must
be made for transportation of sand supply to moulder.
Cubical Injected Moulded Container: This container is cubical in shape and is manufactured via
injection moulding process. This light-in-weight container is widely used in Dairy Industry past 40 years.
It ergonomically designed for handling and transporting material. With account of its robustness, this
plastic is strong, durable, non-corrosive and less prone to withering. On capacity testing it was seen that
this container can carry as much as 22.5kg of sand of volume 11 litres which accounts to twice the
capacity by volume and just 36% increase by weight compared to currently used container capacity. Also
the green sand doesnt stick to container plastic due to cohesiveness between sand and material of
container.

Fig 3.14 Suggested container [=]

Fig 3.15 Container with sand

25

Fig 3.16 Sand container on weighing machine

Currently used container is prone to withering and deformation. It storage capacity is 5.5 litres which is
50% less than suggested vehicle. The material of the container is corrosive and doesnt have a good
handle to carry. Sometimes due to its geometry the sand may fall out of container while transporting.

Roller Conveyer for Transportation of sand:

This conveyor should be installed within the plant near to sand churner and stretched towards New
Moulding Area which is explained in later section of this chapter. The New Moulding area is a dedicated
area allotted to all moulders for moulding small sized and medium sized moulds for the plant.

26

On this conveyor, the helper needs to transport the sand filled container right from sand filling zone
beside sand churner to New Moulding Area to moulder on demand.

This conveyor would achieve the goal of reducing the material and worker movement considerably .If the
company adopts this optimization plan then the helper and moulder will be experiencing a way too less
physical strain which they are experiencing now.

The Helper will be filling the container with sand, lift it to conveyor and push it to moulder. Moulder at
other the end stops the moving container and uses the sand directly from it.
Other good thing about this conveyor is that it doesnt require electricity for its functioning. The rollers lie
on bearing support which helps in the smooth movement of the green sand.

By adopting above plan we can reduce workforce movement and material movement.
If new containers are used on conveyors for transporting green sand then it would decrease the
frequency of supply to moulder. Thereby, decreasing a lot of time and effort put by workers in
transporting material.

27

Fig 3.17 Gravity roller conveyor bench [-=]

3.7 New Mould Box

3.7.1 Function of a Mould Box
Mould box is use to pack the sand with the pattern such that close dimension of the cavity is obtained
when pattern is removed from mould box. The upper part of the mould box is Cope and bottom one is
Drag. Between Cope and Drag, parting line exist inside the mould box where the melt poured flows
through path made by moulder while moulding.
Mould box pair should be accurately aligned and engaged such that there remains no gap between two
mould boxes. This ensures that sand doesnt come out of mould.
During pouring these mould boxes experience melts metallostatic forces due to which the cope part starts
to repel from the drag. This causes leakage of melt from the parting line after or during pouring if dead
weights are not kept enough.
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Fig 3.18 Current mould box

3.7.2 Reasons to use New Mould Box

Leakage of Melt during pouring due to deformation of mould boxes which leads to dis-alignment of
mould boxes. This dis-alignment creates open space for the sand and melt comes out during pouring.

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Fig 3.19 Melt leakage due to deformation and dis-alignment of mould box pair
The worker face handling difficulties because the mould box have corroded and have thin cross section of
handle which gives immense pressure on the hands of worker while lifting it. Moulding sand slips out
while lifting mould box due to low adhesiveness between the inner walls of mould box and green sand.
Reduced adhesiveness is due to corrosion on inner walls of mould box.

Fig 3.20 Corroded mould boxes

3.7.3 Features of New Mould Box

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We suggested them to use new mould box which can provide following features in order to prevent the
above mention issues currently the company is facing with their present mould boxes. New Mould Box
must have following features:

Proper Edges.

Corrosion resistive.

Proper alignment.

No Gap or space after engagement of Mould Boxes.

Strong Handles.

Good Heat Dissipation.

Robust towards Mishandling.

Fig 3.21 Sample of proposed mould box[oip]

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Cost: Rs 2644/item
Specification:
Size: 300x300x100mm
Brand Name: SMART

3.8 Mould Box Storage

Casting companies are constantly in a need of pattern every time they start the process. So organization
and handling of mould boxes is an important aspect. But here currently the mould boxes arent properly
organized and do not have a designated storage place. This increases the time to find one when needed. It
also causes damage to the mould box and its misplacement as well.
32

Fig3.22: Mould Boxes in NFF

The new mould storage area will help organize all the mould boxes and in accessing the desired pattern in
very less time.

Fig 3.23 Stacking of mould boxes

Fig 3.24 CAD Model of hanger

New Mould Boxes must be stacked properly. The ones which are used regularly must be hanged on the
hanger as shown in the above figure for fast and easy access .This also organizes the mould boxes
effectively hence reducing search time.

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3.9 Moulding Area

Moulding area is a spot or place where the moulder makes moulds using pattern, green sand, white sand,
mould box, rammers and other moulding and gate cutting tools
Currently, moulder doesnt have a dedicated moulding area where he can work with all of the above
materials and tools in order to make mould with higher productivity in terms of time spent on producing
each mould.
Moulder has to fix a moulding spot in the plant depending on the available space in plant. Then he
collects pattern from pattern storage rack. After that he goes in search of mould box for its pattern. After
gathering mould box, he brings up the tools from the last moulding spot.
After gathering all tools and materials, helper provides sand to moulder to his moulding spot every now
and then depending on moulders call for sand.
This much movement of worker along with materials adds to the time and effort put upon to do moulding.
Rather a dedicated area for moulding could spare this problem where moulder has his tools, pattern,
mould box ready to use on the comfortable workbench.
In previous section of Supply sand to moulder, in that it was concluded that the conveyor might help
into reducing movement of worker and material and ensures continuous supply of sand by helper through
connection of sand churner to new moulding area directly.

3.9.1 Benefits of New Moulding Area

Reduces Work Force movement drastically.

34

Eliminates the making of flat area before starting moulding which may sometime take 5mins10mins.

All required raw materials like sand and pattern for moulding comes to one place reducing
movement of workers

Tools and other items club at one place, so it results in easy and fast access of those items.

Ergonomic Design of moulding area leads to the effic6+ient working of workers.

Search time of required mould box is reduced due to proper organisation.

As a whole since worker movement is reduced, pre-process materials is accessed faster and flat
area is already present and maintained easily we estimate that there might be drastic increase in
production rate of mould.

3.9.2 Features of New Moulding Area

Elevated roller workbench:
Moulding Base: It is 75cm above ground and 2.5 meter in length. Rollers in row make up base for
moulding. The Rollers has space between each other called Slots. Rollers make easy for movement of
mould box especially while turning it by 180 degree .The height of base makes easy for moulders to work
for more time without straining their body than the work done with current position.

35

Fig 3.25 Current position of moulder while moulding

Fig 3.26 Position of moulder working on roller workbench

Sand collection plate: Moulding must be started with a flat board kept on rollers of workbench. While
moulding, sand which are not required and removed from the mould tend to pass through the slots and fall
on the sand collection plate.

36

From where the un-used sand is collected and dragged into the hole ,where the sand falls into the sand
Box as shown in the moulding Area image below. This reduces the wastage of un-used green sand.
Tool Keeping & Drawers: The roller workbench also has space on the right hand side to keep the
frequently used moulding tools and white sand which is ergonomically good whereas on the left hand side
drawers are there to keep inventory of tools, sand and other miscellaneous items.
Suspended Pneumatic Rammer:The pneumatic rammer is suspended overhead and is hanging at the
centre of the 2 conveyer table for easy access to both the worker as and when required. The rammer
retracts back to its original position when not required by worker.
Storage of Pattern and Mould Boxes:These storage space are kept below the sand collection plate and
is mainly meant for the mould boxes and pattern which are in immediate use. This storage is temporary
and contents of the storage keeps on changing daily.

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Fig 3.27 Sketch layout of New Moulding area

3.10 Plant Layout Modification

Fig 3.28 Current plant scenario

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Fig 3.29 Current Plant Layout

The above picture gives a rough idea of the current plant layout. In the plant, there are two unusable
machines because there is a need of excessive maintenance in these machines so company wish to remove
it from the plant. Taking that in consideration and also proposed new mould box storage and moulding
area .There will be a major change in the plant if all the above plan isexecuted in future.

Fig 3.30 Non-operational sand churner and cupola furnace

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Fig 3.31 New Plant Layout

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Chapter 4
Evaluation & Calculation
4.1 Ramming Calculations

Table
4.1 Comparison of hand rammer and pneumatic rammer
Y Axis- Time (in seconds)

X Axis- Type of casting (size)

According to the approximation done, time saved (in percentage) by using pneumatic rammer
over the current is:66% in small castings
72% in medium castings
83% in large castings
From the above bar chart we infer that as the size of casting increases (from small to large) the
time reduction percentage also increases. This is due to the fact that the workers get worn out
after repetitive action of ramming the sand hence their efficiency decreases as size increases and
time passes.
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4.2 Evaluation of Removing Pattern from Mould

The basic purpose of changing the current pattern removal was to avoid damage caused to the
Cavity and to reduce the skill require doing the task. The new technique will help to remove
pattern firmly placed pattern in the moulding sand quickly such that the dimension of the cavity
change is minor and pattern damage is reduced substantially compared to the current used
technique.

4.3 Material and workers movement evaluation

Currently the worker along with tools and materials move about more than 57.84 metres used
while moulding a small size casting but by implementing our new plan we estimate that the
workers total movement will decrease by 67% to 18.65 metres for producing same size casting
as per study given below.
Distance (metres)
Current Layout
57.84
New Layout
18.65
Travelling Distance Saved
39.19
Table 4.2 Reduction of workers movement

4.4 Current Flow process in plant

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Fig 4.1 current flow process chart

4.5 Modified Flow process in plant

Fig 4.2 Modified Flow process chart

4.6 Increasing Container Capacity

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Old
Mass Capacity (kg)
Volume Capacity

New Container

Container
13.5 kg
0.0055m3

21.8 kg
.011m3

Increase in

Increase in

Quantity
8.3 kg
0.0055m3

Capacity
61%
100%

(m3)
*Mass capacity has been slightly reduced to remove the weight of the container and account for
sand only.
Table 4.3 Effects due to container change
From the table above we can deduce that there will be a considerate amount of decrease in
workers movement with a 100% increase in volume carrying capacity of the new container.

4.7 New Mould Box Calculations

Approximately 40% of melt leakage happens due to improper mould boxes and misalignment of
the same. This can be avoided by using new mould boxes
TABLE KEY
Cost = Amount of Material * Rate per kg
Total Cost = Scrap Iron Cost + Pig Iron Cost + Flux Cost
Melt Leakage Cost = 17% * Total Cost
Savings(on melt) = 40% * Melt Leakage Cost
Mould Boxes Cost = Cost of 20 new mould boxes, Rs 2644/box
Actual Savings = Savings(on melt) - Mould Boxes Cost
*All data collected is for per annum basis from April14 to April15

Amount of

Rate per kg

Cost
44

Material
Cast Iron
Pig Iron
Flux
Total Cost

(kg)
106150
62650
29

(Rs)
27.5
32.5
380

(Rs)
29,19,125
20,36,125
11,020
49,66,270

(Rs)
Melt Leakage Cost

8,44,266

(Rs)
Savings (on melt)

337706

(Rs)
Mould Boxes Cost

52880

(Rs)
Estimated Savings

284826

(Rs)
*All data collected is on per annum basis from April14 to April15
Table 4.5 Cost saving calculation due tom use of proposed mould boxes

4.8 New Moulding Area

4.6.1 Dimensions of New Work Bench and Conveyor
Length 2.5m
Width 0.6m
Height- 0.75m

4.9Evaluation of Labour cost

Currently for moulding, the staff comprises of 5 moulder and 2 helper. It is estimated that only 5
worker staff is enough to produce current output produced by staff of 7.
Estimated Salary Saved of 2 Workers

45

Task

Allotted Staff
Salary/day
(Rupees)

Current

Annual

Estimated

Estimated

Annual

Staff

Labour Cost

Staff

Annual

Saving of

(worker)

Labour Cost

Labour Cost

Rs 2,70,000
Rs 90,000
Rs 3,60,000

Rs 1,80,000
Rs 0
Rs 1,80,000

(worker)

Moulder
Rs 300
5
Rs 4,50,000
Helper
Rs 150
2
Rs 90,000
Total
7
Rs 5,40,000
* Salary is accounted for 300 days a year.

3
2
5

Table 4.6 Yearly salary calculation of worker

4.10 Evaluation of Mould Box Storage

As estimatedthe new mould box storage area will help in accessing every mould box within 3060 seconds .Currently it takes anywhere between 5-10 minutes to find the required mould box.

Chapter 5
Summary

To summarise the project we have helped NFF find a way to optimize its plant and increase its
productivity using Work Study as a tool. Following the work study method, we have studied the
46

current practice/processes at NFF, done its time study and then evaluation of those processes was
done where we found NFF was lacking and maximum increase in productivity could be achieved
with as less investment of time and money as possible. We have recommended a few changes in
the ramming process where we sought to replace the hand rammer with pneumatic rammer. In
the pattern removal technique we have suggested L-shaped grooved tool which decreases the
time to do remove the pattern. We have designed a new plant layout which has reduced workers
movement and material handling considerably and also changed the sand carrying container for
the same purpose. We have also suggested them to buy new mould boxes to cut short the
material wastage by reducing melting leakage during pouring process and also designed a new
storage area for the new mould boxes to help maintain them and access them as quickly as
possible. After doing an approximated analysis of this we have found to save material, labour
work and cost relating to them and also time and movement of material and labourer for the
same process.

5.1 Summary Table

Material
Cost Savings
(Rs)
Time Saved(sec)
Movement

264826

Labour
180000

Total
444826

500
39.19

500
-

Reduced(meters)
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*Time is being considered for making a small casting. Workers speed is considered to be 0.7m/s.
Average time for every process is being considered.
*Movement is considered for a single complete process.
Table 5.1 Final Result

REFERENCES
[].George Kanawaty.(1992) Introduction to Work StudyIndustrial Labour Organisation.
[].ASM Handbook Volume 15 Casting
[] Supplying Pneumatic Rammer:PG 21
Samirika Infrastructure PVT LTD
ISO 9001:2008 Certified, Vadodara, Gujarat
Supplying Compressor And Tank: www.Industrybuying.com

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[] Link: http://www.tolexo.com/smart-fabricated-mould-box.html?utm_source=buy-ondir&utm_medium=imreferral&utm_campaign=im-buy pg 30
[]www.ebay.com
[]youtube links

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