1. Importance of Maintenance HPDC Foundry

2. 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

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

4. Machine Maintenance Plan
Salient Features

5. 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)

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

7. 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

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

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

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

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

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

13. 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

14. 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

15. 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.)

16. 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

17. 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

18. 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

19. 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

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

21. 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

22. 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)

23. Thank You!