Brakes India Material conservation - GreenCo India.pdf · %udnhv ,qgld 3yw/lplwhg)rxqgu\ 'lylvlrq...

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Brakes India Pvt LimitedFoundry Division

Slide No 1Together Towards Excellence



Project Title

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Trigger of the Project

Vision

Policy Deployment Process in BIF

Policy Deployment ProcessLTO, MTO and Yearly Objective and

strategies identification Process

Brakes India Private Limited Issue 1

Foundry Division 2018-19

Oct-19 Oct-19 Mar-19 Mar-18 Mar-19 Oct-19 Mar-19

QA QA CFT QA/CFT QA QA QA

3. Restore the growth trajectory to a tleast 15% CAGR

4. Achieve Number one pe er ranking in qua lity 5. Achieve energy security at competitive price

Improving Surface finish - Both inside and outside of the castings

1&2 S in fettling subcontractor end

Automation of inspection activieies

Reducing machining Rejections Rejections and rework in bearing housing. need to totally eliminate re work and reduce casting and ma chining re jections

Introducing best systems in QA / Mfg

MANAGEMENT FOR OBJECTIVES - 2017-18

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1. Remain cash positive and genera te Rs 100Cr over 3 year period

2.Achieve PBT to net sales > 11%

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Guidelines

Yearly Objectives & Strategies

Material Conservation in Cold Box Core Manufacturing(Resin / Activator / Catalyst) and Extending to our supply chain



Uniqueness of the Project

Achieving closer to world class benchmark levels with locally available resources.

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MATERIAL BALANCE - SAND FOUNDRY

1.Steel Scrap,2.Foundry returns,3.Machined Borings4.Pig iron,5.Alloys,6.Others.

1.Bentonite2.Coal Dust3.New Sand

1.Resin2.Activator3.Catalyst4.New Sand



Sand Foundry % share of Raw Materials by weight

14.11

84.69

1.06 0.14

Sand Foundry % share of Raw Materials by weight

Melting

Molding

Core

Others

Melting: (Steel Scrap / Foundry Returns / Machined Borings / Alloy Additions / Pig Iron * / Others)

91.75 % our Melting Input is recycled material.

Moulding : Return Sand / Bentonite / New Sand / Coal Dust *

97.16% Moulding input is recycled return sand.

Core: New Sand / Resin / Activator / Catalyst *

Reduction in Resin / Activator / Catalyst * chosen towards material conservation.

* Note:- Virgin Material

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• Phase-I - Achieving National Benchmark. Completion as per plan(March-18)

• Phase-II - Progressing toward world class bench mark. Target : March-19

Date of commencement -

Date of completion of

project compared with initial planned

dates.

Date of commencement -

Date of completion of

project compared with initial planned

dates.

Major milestones of project

Major milestones of project

Project Introduction

• Collecting data on best practices - Jan -17 • Verification with best practices - Feb-17• Improving gap areas - March & April-17 • Conducting DOE - April & May-17 • Implementation & Monitoring - May-17 to Mar -18



Core is used to make inner profile / undercuts of the castings.

The shape of the core is made same as the inner profile or under cut

required.

Cores get collapsed after forming the profile after pouring metal into the

mould cavities.

Most of the cores made up of silica sand except in some cases, metal /

ceramic, wax. etc

Casting Inner Profile

Core

What is core

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Core Simulation Core Box Design_ toolingCore Box tooling

Manufacturing

Core Box tooling set up in the machine

Core Manufacturing Core Manufacturing (Process parameter control)

Core de-finning – (Removal of fins / Projections /

Inspection)

Incoming Quality control of Raw materials

Core painting & Drying(Control of process

parameters)

Core Inspection , Storage & FIFO control and Transportation

Sand mixing in the sand mixer

Cold box core Manufacturing process flow

Best Practices in Core Manufacturing



We would like to identify / use best practices in all aspects of cold box core manufacturing to

conserve materials. The key activities are

• Tooling Design and Tooling Manufacturing

• Core Manufacturing & Process control

• Equipment Maintenance

The following slides will give the gist of best practices identified. These were evolved by PDCA, DOE and other tools before identified as Best Practices

Best Practices in Core Manufacturing

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Tooling Simulation

Core simulation software usage in design stage

Foundry code 7936_37 CoreCustomer Part

NumberA006V055 / 042

Description Body casting

Project Name 17inch OL

Process type Cold core - Vertical

Shooting pressure 3000milli bar

Shooting time 3 seconds

Core weight 0.47 kg

Sand Silica

Ejector 10mm dia

Vent 6&8mm dia

Fixed Half Movable Half Side View



Tooling Material: Steel alloys and Cast iron is best for core box tooling

Blow tubes :

• Blow tube size and location are important

• Preferred – Large, straight I.D. or neck – down tubes for very small, light cores.

• Preferable : low shooting pressure 35 to 50 psi.

Tooling control – Vents

• Use Self cleaning vents.

• Total vent area should be 80 % of the total blowing area.

• Should not be placed in the same direction of the blow.

• Required to be cleaned regularly with air and brush..

• Plating of core boxes for finish and wear resistance.

Best practices in Tooling Design and Tooling Manufacturing

Blow Tubes

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Sand control : • Grain size (Best for strength – Round / Best for Veining control – sub angular )• Grain Shape & Fines content in the sand • ADV and pH • Contaminants• Sand temperature between 50 to 105° F. Best - 70 to 80° F• Moisture should be close to Zero

Best practices in Core Manufacturing & Process control

Sand Grain SizeCore Quality Control:

Basic tests for core Quality

• Bending & Tensile strength • Scratch Hardness test on the cores

Scratch Hardness testing Tensile strength testing Bending strength testing



Process control:

• Automated controls of sand mixing time

• Auto controlled resin and Activator additive system

• Periodical calibration of addition quantity & mixing time.

• Locating pumps and tanks in area having even temperature

• Air Dryness is important since moisture can condense in blow magazine.

• Catalyst (Amine) vapour & air temperature is important because, warmer the carrier gas, the richer the catalyst

mixture.

• Install catalyst gas generator closer to the machine and Insulate the Catalyst(amine)pipe lines to avoid

condensation.

• Optimised gassing chamber size for reducing catalyst wastage.

• Consume prepared sand with in the bench life.(< 40 minutes).

• Ensuring sand mixer blade side & bottom gap.

• Effective removal of sand fines through suction blower in the sand feeding system.

Best practices in Core Manufacturing & Process control

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Tangible benefits.

Sl No ParameterUnit of

MeasurementReduction in Quantity

Cost Benefit In INR Lakhs / annum

1 Resin Kgs 10970 10.0

2 Activator Kgs 9960 19.25

3 Catalyst Kgs 4990 8.06

4 Thermal Energy Lts 1375 0.96

5 Carbon Ton of CO2 -eq 3.7 -

6Core rejection

reductionKgs 106340 5.32

Total savings for the Year INR in Lakhs 43.59

Hazardous Chemicals consumption reduced by 25920 kgs

Project Savings / Annum



Intangible benefits:

Sl No Benefit ParameterUnit of

MeasurementActual value Remarks

1 VOC at work place PPM 14 IAQ

2Reduction in

EmissionTon of CO2 -eq 3.7

Reduction in scope 3 emission

3 Electrical energy Units / Annum 1529Reduction in scope 3

emission

4 Thermal energy Kcal / Annum 8501760Reduction in scope 3

emission

5 Water Lts / Annum 11664Reduction at supplier

end

6 Employee Motivation Presented the project in Sastra University Kaizen competition.

7 Skill Upgradation Expertise in cold box core Manufacturing

8Reduction in waste

generationNo of barrels 823

Also reduction in Scope 3 emission

Hazardous chemical used containers reduced by 823 barrels

Project Benefits

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Replication potential and progress of project

Sl No Company Where When Implemented

1 All suppliers to BIF Sholinghur May-17 Yes

2Flometallic India pvt

ltdJhagadia

June-17Yes

3 Brakes India- Unit-3 Naidupeta July-18 In Progress

4This project can be implemented in different companies of mainly Ferrous / Non

Ferrous Foundry cold box Core Manufacturing.

Horizontal deployment potential



Technical paper presented in conference on Core technology organized by ARKEY conference. This is also published in Journal for Aluminum castings technology.

Published in Journal for Aluminum castings technology.

Sharing the best practices within the sector

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Challenges faced Actions1.Establishing simulation software for effectivedesigning of core boxes.( sand shooting, ventinglocation and blow tube diameter).

Utilization on Magma software for core simulation.

2. Availability of good quality core sand. ( Grain shape,Clay content).

Removal of sand dust using dust removal system

3. Input air quality Air dryer provided to remove moisture in the air

4. Maintaining amine in vapor state till it reaches corecavity.

Amine pipe line length shortened. Pipe line insulated & additional heater near gas

chamber provided. Gas chamber size reduced.

5. Core Quality (strength) monitoring & Conducting DOE.

Separate lab established for Core quality (strength) monitoring and DOE conducted at different level of additions.

Technical

Challenges faced & Actions



Challenges faced Actions

Training the employees and suppliers in line with our requirements / Implementing the improvements ( paradigm shift).

On the Job training provided for all the employees & suppliers.

Our representatives are visiting suppliers on daily basis to monitor their performance & educating them.

Knowledge sharing with best core shops. Visited ASK chemicals, Europe for learning the best

practices.

Updating the knowledge on the improvements across the world.

Visited GIFA & IIFC for learning the new developments

Administrative:


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Maintenance:


Challenges faced Actions

Maintenance of core boxes for effective venting, sealing of two core box halves and cleanliness.

For ensuring vent cleanliness, new tool provided for vent cleaning

Ice blasting introduced for core box cleaning Periodical inspection of core boxes.

Maintaining the efficiency of the sand mixer. Monitoring blade and bottom plough worn out

Consistency in the auto dosing of Resin, Activator & Catalyst.

Periodical calibration of Resin, Activator, Catalyst addition & mixing timer.



% Of Resin

Target :- Achieve world class bench mark on specific consumption in Resin , Activator

& Catalyst.

Sl No ParameterNational Bench

marking International Bench

marking Brakes India Private Ltd.

Foundry Division

1 Resin % 0.66 0.55 0.69

2 Activator % 0.66 0.50 0.65

3 Catalyst % 0.12 0.092 0.12

Bench marking on % of resin, activator and catalyst trend with respect to sand

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To achieve international bench marking results by the following initiatives.

1. Develop new generation Resin / Activator in collaborative effort with Resin / Activator

manufacturers to reduce the material consumption further.

2. Providing sieve shaker to remove the fines content less than 100 microns in the sand

completely.

3. To use thermal reclaimed sand for core making.

Way forward



• Mixer maintenance has greater influence on core quality, Resin & Activator consumption.

• Fines content in the sand has huge impact in consumption.

• More sand dust is generated during Pneumatic conveying of sand.

• Grain shape of the sand has greater influence on consumption.

• Use of simulation software for core box design greatly reduces the number of trials and

rejection.

• Location of the Catalyst generator, insulation of Catalyst pipe line, Air quality, size of the

gassing chamber have greater impact on consumption.

Learnings’

Learnings’ from the project implementation.

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Thank you

Brakes India Material conservation - GreenCo India.pdf · %udnhv ,qgld 3yw/lplwhg)rxqgu\ 'lylvlrq...

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