Perfect Process Synchronization and Precise Work Orders

Challenges faced in the foundry (Iron casting):

The melting and molding deployment processes are synchronized for the casting process on the caster.

Just in time delivery taking into account:

  • Use of multiple furnaces with only one connection to the power supply for the heating up (sequential)
  • Different capacity (batches) of several furnaces, secondary metallurgy, transfer pans and molds
  • Lock the transfer pans from the tap (furnaces) and the transferring via the secondary metallurgy (magnesium pan) until the casting (casting line)
  • Short lead time from tapping to avoid cooling
  • Limited buffer zone on the caster
  • Timely deployment of the models, cores and molds with limited resource capacity

 

The melting operation and molding deployment are synchronized with each other. Accurate and meaningful work orders for each resource are created and adapted dynamically and optimally if changes are made or reschedules are exercised.

The graphical display of the item structure illustrates the process flow and the merging of "form-cast casting ready" and melt.
The graphical display (detailed here) shows what resources and sub-ressources are used. It also visualized what alternative ovens are available. The scheduled furnace is occupied until the entire furnace charge is cast in the secondary metallurgy.
Resource groups have individual shift models. For melting operations include the ovens - to form the core provisioning route, forming section core supply and model deployment.
What days are working in what work shift: In the calendar, the calendar entries are performed for resources with the appropriate work shift.
The customer requirements are imported standard orders from the ERP system. Then Asprova creates an automatic replenishment order for semifinished products depending on the maximum lotsize, corresponding to the different maximum levels of intake.
In Oven1 you can see the process heating up (dark green bar) and sample taking with subsequent overheating (red bar). In the following process Mg treatment on the resource secondary metallurgy a furnace batch of 6910 kg in 2 filling quantities is decanted and concentrated in the magnesium-pan (maximum lot size 4000 kg). The Oven1 remains occupied until it has completely emptied. Only then the heating up for the next furnace batch can begin. The remainder on the secondary metallurgy of the first batch and the second batch of 2910 kg is transported according to customers' order quantity with the ladle and bottled on the casting line.
For the filling on the casting line a prepared mold is required. The mold is composed of core, model and sand mold. The capacity of the core range is limited and the mold must be provided to the teeming line just-in-time to prevent the cooling of the melt. These processes are scheduled backwards (the melting operation forward).
The relation between the furnance process to the foundry (landle) and mold deployment to foundry are visualized in the Resource-Gantt-Chart.
Same orders with a relation to the respective furnace batch are highlighted. You can recognize the synchronisation of merging processes.

The plan is simulated for several days/weeks/months in advance. Customer-specific changes and disturbances are considered dynamically.

Some of our customers: