From traditional molasses to green sand high pressure moulding ver3 jainsons

From Traditional Molasses to Green Sand High Production High Pressure Moulding Case Study of a Micro Foundry producing MI Pipe Fittings, Decorative Ornamental Castings

Presented by: Dinkar Jain & Ankush Jain, Partner, Jainson Industries, Jalandhar

The Pros & Cons of Molasses A Qualitative View

The Pros

• • • • •

Better Surface finish Low Capital Investment Ease of Reuse of Sand Longer bench life of mould Flexibility for variety, quantity and pattern quality • Lower pattern costs

The Cons

• Low Productivity • Human Skill Dependant • Casting inconsistency for weight and dimension • Cannot service volumes • Mechanisation not possible • Poor strength in green stage • Not worker friendly • No process control • Special storage for molasses

The difference of changeover from Molasses to Green Sand with High Pressure Traditional Molasses Moulding

Green Sand High Pressure Moulding

The process before change

After Implementation

Green Sand High Pressure Moulding The Results Achieved – Production Moulding & Pouring

Production Capacity in EXISTING Area of 170 m2 • Increased from 55 MT/month to an Installed Capacity of 100 MT/Month • Approx 2 fold increase in production in same area in 12 hours shift working. Another 100 MT increase feasible in same area with 2nd Shift.

Productivity in MT/man/month for the same product mix • Earlier productivity was 2.33MT per man/month • With a team of 10 persons per shift we have already reached 10 MT per man/month

Green Sand High Pressure Moulding The Results Achieved - Manpower Change in Manpower Skill Needs

• Working with mechanised & automated plant the skill needs shifted from domain specific skills of moulding to generic skills of operation & maintenance • The pool of persons available has increased Better Working Conditions – OHSAS Compliance • Smoke free working • Improved illumination, from dark environment and 2 whitewashes every year has reduced to light whitewash once a year.

• Operators working in better and safer conditions.

Green Sand High Pressure Moulding The Results Achieved – Process & Product

Controlled System • Process is measured and controlled in Green Sand Process • Expert process guidance, online remote support for system available.

Improved Weight & Dimension Consistency • The inconsistency in small pipe fittings and decorative castings due to human error eliminated, thus saving in rejection and rework by 7% • Reduced casting shift has reduced rejection and grinding activities • Weight variation reduced from 10% to 2% (direct cost benefit)

Green Sand High Pressure Moulding Technology Outweighs Traditional Process FM Green Sand Process

Hand Moulding Molasses

Our Learnings on the Way  After setting up FM line, Jainsons Industries is considered as a leading foundry in Jalandhar – a great differentiator

 Exposure to High Pressure & Green Sand also increased

knowledge in sand testing, image analysis, spectrometer use, pattern making in PU etc – it was a paradigm shift from traditional process to modern process

 We should not blindly copy, there is always a learning curve, and a path to success

 Without technical knowhow & understanding, taking quantum technology jumps not recommended – thorough study of systems required

 Importance of business partnership, transparency & knowledge sharing between foundry and machine supplier

 The effort and energy required for implementation and the need of trained manpower is important

Jainsons Industries thanks IIF for giving an MSME a Platform to share their Case Study