How one results-oriented foundry applied itself

Unsatisfied with controls being achieved in the moulding department, Haworth Foundry managers Steve White and Lee Chase set about improving matters to ensure productivity was not adversely affected.

Haworth Foundry is a sand and die foundry in the UK employing around 25 people. An independent family firm, the company has been in business for over 40 years producing high specification, safety critical aluminium castings including components for aerospace applications, parts for pressure tight applications, midvolume production castings for the automotive industry, fluid coupling castings and a range of non-standard and intricate castings for a variety of applications.

Being able to produce castings consistently and reliably is vital to operations, so Haworth already uses fully framed pattern equipment and has invested in a semi-automatic moulding system encompassing a computerised sand mixer and rollover moulding sand dispenser to minimise operator induced variations.

Moulds are produced using a three part, polyurethane no-bake resin system. Inconsistency in setting times in the moulding section was an issue causing particular concern. During hot or cold weather spells the mix, which was nevertheless calibrated for temperature variations, was giving inconsistent curing times and variable mould strengths. This was leading to poor productivity since the moulders were either standing around waiting for moulds to set or producing moulds that were of inconsistent strength. The foundry was not able to achieve the control it was seeking despite the team carrying out various investigations into the binder system and equipment being used….

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Acknowledgment to Pam Murrell.