MxD is working with a foundry where currently the quality of the metal pouring process is heavily reliant on operator skill. The foundry has the capability to simulate the success of its pours, but lacks the data and process control to know if pours are being done within the simulated thresholds. Pours done outside the simulated thresholds lead to either increased rework or scrap.
About the Project
A manufacturer in the Midwest operates a foundry working with metals such as aluminum, brass, and steel. The foundry has 3 different size furnaces which can either feed a bottom-pour ladle or a kettle-pour ladle. For the kettle-pour ladle once material temperature is confirmed the ladle is moved via crane and 2 operators on foot to the molds for pouring. Due to the intricate nature of moving the ladle and pouring the metal, the metal can cool down to a lower temperature than expected prior to pouring all the molds. Similarly, because the pouring is done via turning a wheel the metal may be poured faster or slower than anticipated. In either case, the operators lack the feedback to know if the metal is out of the ideal threshold.
Note: All project work must be performed in the United States.