Importance of Maintenance HPDC Foundry

Definition of Maintenance Activity to ensure uninterrupted Production Stipulation of each activity Maintenance of records of each activity Stipulation of frequency of activity Adherence to Implementation of stipulation Audit of implementation Maintenance as a means of Quality Assurance

Equipment Maintenance Machines (Casting, Pneumatic, Trimming) Furnace & Burner Tools (Dies & Molds) Metal Handling Tools and Equipment Instruments Safety Equipment Administrative Equipment Environment Records

Machine Maintenance Plan Salient Features

Areas of Attention: Control Panel Oil Pump Water Cooling Circuit Tie Bars Platens Hydraulics Control Valves Accumulator Circuit Pressure Gauges Cleanliness (Leakages, seepages, oil stains)

Tool Maintenance Plan Casting Dies and Molds Auxiliary Mold Equipment (Sleeve, Bush, Plunger) Trimming tools and equipment

Maintenance of Metal Handling Equipment Fuel Storage Equipment Fuel Dosing Equipment Fuel Supply Civil Works Fuel Pumps Heating Equipment (burners, heating elements, etc.) Furnaces (lining and insulation) Temperature Control Instruments Crucibles Metal Storage and identification of alloys Flue Gas discharge Equipment

Measuring Instruments Importance of Instruments Tools and Gauges Importance of Calibration of Instruments and Gauges Frequency stipulation Adherence to implementation Record Maintenance

Maintenance of Safety Equipment Minimum Equipment Required Importance of Safety Equipment Testing of Safety Equipment Record Keeping Safety Audit

Maintenance of Administrative Equipment Computers Files and Folders Importance of “Hard Copy” Accounting System Maintenance Audit

Environment Maintenance Pollution Control Health Records of Human Resource Environment as a means of Cost Control

Records Record keeping as a means of control Importance of Audit Model Records

Model Records (Machine Maintenance) Data to highlight Oil Pump Condition Oil Level Record Oil Condition Test Oil Consumption Record Response to Pressure Setting Motor Temperature monitoring Condition of Electric Connections Pump Cooler Condition Water Discharge Water pipe Decal king Cooling Water levels in Tank/Reservoir

Model Records (Machine Maintenance) 2. Machine Panel Data to highlight Cleanliness Condition of Circuit Data Cards Condition of indicator bulbs Condition of connectors Condition of fuses Voltage and current readings Response of the machine parameters to microprocessor setting

Model Records (Machine Maintenance) 3. Condition of Machine Elements Data to highlight Condition of Tie Bars Die Height Setting Tie Bar Lubrication Report Condition of Platens Water Cooling of Platens Condition of T-slots for Die Clamping Condition of Hydraulic cylinders Reportage of oil leakage observation and repair instruction Condition of Pressure Gauges (incl. Response to differential pressure setting) Accumulator Gas pressure check and replenishment Condition of electromagnetic valves Condition of limit switches/ sensors Cleanliness (oils, lubricants, metal flashes, etc.)

Model Records (Die Maintenance) Features to highlight Daily Check-list Weekly check-list Die Hardware Checks Reportage of inspection to concerned authority Implementation report of repairs undertaken

Model Records (Maintenance of Hardware for Fuel Equipment) Features to highlight Fuel tank Fuel level check Fuel leakage check Fuel sediment inspection Fuel -flow inspection Burner inspection for fuel flow Burner nozzle inspection and reportage Burner Setting of correct Fuel/Air Ratio Record of Daily Fuel Consumption

Model Records (Maintenance of Furnace) Features to highlight Crucible condition Reportage of weekly Crucible rotation Brick Lining Condition Record of Heat insulation condition by checking the shell temperature Checking and calibrating Thermocouples Check of condition of insulating sheathing of Thermocouples that are dipped in liquid metal

Model Records (Instrument Calibration) Features to highlight Record of stipulation of tests and testing frequency recommended by original manufacturer Instruction sheet of calibration procedure for each instrument Record of calibration performance of each instrument Instruction of next calibration date Audit report of calibration of each instrument

Model Records (Die Loading) Table of this data sheet is separately available for study

Model Records of Safety Standards Features to highlight List of Safety Equipment Record of stipulation of tests and testing frequency recommended by original manufacturer Instruction sheet of test procedure for each equipment Record of performance of test of each equipment Instruction of next testing date Audit report of calibration of each equipment

Epilogue Environmental Responsibility Foundry, in its total functioning, is a pollution prone industry. The work force involved in production activity is vulnerable to tough physical activity and health hazards. But, it doesn’t mean that it cannot be improved. A good working condition can always be created with the strong managerial will and inclination. Any cost involved in creating clean working ambience is an investment and not a cost. An improved quality of output and productivity is an undisputed outcome in a clean and well-lit foundry. Maximum use of natural light, proper exhaust system for flue gases and lawful disposal of waste, aeration are a few examples of the cheapest methods of achieving the goal. Mechanization in foundries must be well aimed and targeted to reduce physical effort that can be utilized to maximize per capita output with least effort. This is best done by understanding the problems involving the workforce by constant tête-à-tête. This, in modern parlance, is called rationalization. Though, this term is often misinterpreted as replacement of manpower by automation. Due to the very nature of work it is a bad practice to ignore safety. Clothing and equipment of safety are bare essentials. Clean and well lit die casting shop (observe light and cleanliness)

Thank You!