Energy-saving Operation in Foundry Kenji SHI OTANI Ishikawa - - PDF document

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Energy-saving Operation in Foundry Kenji SHI OTANI Ishikawa - - PDF document

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Energy-saving Operation in Foundry Kenji SHI OTANI Ishikawa Malleable CO., LTD Company Profile Establishment May, 1953 Capital 48 Millions JPY President Tetsuo SHIOTANI Number of employees 134 Business Casting Sec.

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SLIDE 1

Kenji SHI OTANI

Ishikawa Malleable CO., LTD

Energy-saving Operation in Foundry

  • Establishment

May, 1953

  • Capital

48 Millions JPY

  • President

Tetsuo SHIOTANI

  • Number of employees

134

  • Business

Casting Sec. (Manufacturing of casting) Machinery Sec. (Machining of metals

  • f casting etc.)

Import Sec. (Importing or selling of products made in China)

Company Profile

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SLIDE 2

Production Capacity: 1,600t/ month

ISHIKAWA Pref., Japan

Production Capacity: 6,000t/ month

Suzhou City, Jiangsu Province China

Total Production Capacity 7,600t/ month

Production Base Site Map

道 路

Melting: 4t High-frequency induction furnace 2 sets Molding machine: DI SA230B Production capacity: 1,000t/ month

West Factory Machine Factory East Factory

Melting: 3t High-frequency induction furnace 1 set Molding machine: APS (660 x 540) Production capacity: 600t/month

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SLIDE 3

Equipment Specification and Material Constitution in East Factory

APS of Shintokogio made (Manufactured in 1984) (660 x 540 x 180 x 180) High-frequency induction furnace Made of Fe 3t/2200kw Casting weight 10kg/flask~ 60kg/flask Number of production items 1,500 items Minimum and maximum number

  • f lot flask per month

5~ 300flask/product

Equipment Specification and Material Constitution in West Factory

DISA230B (650 x 535) (Manufactured in 2007) High-frequency induction furnace Made of Fe 4t/3500kw 2 sets with 1 power source (Melting, heat-retention) Casting weight 10kg/flask~ 40kg/flask Number of production items

  • Approx. 100 items

Minimum and maximum number of lot flask per month 50~ 14,000flask/product

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SLIDE 4

Percentage of CO2 emissions

FY 2011 Electric 95.7% Kerosene 2.0% (Paraffin) Light oil 0.4% LPG 1.9% Electric 95.9% Kerosene 1.8% (Paraffin) Light oil 0.4% LPG 1.9%

Report on Energy Saving at Our Company

FY 2012

【西工場】契約電力: 4 5 k W

Melting furnace 80%

【東工場】契約電力: 3 k W

造型・ 砂処理 1 3 ％

Dust collector 7％ Compressor 3％ Processing machine 2％ Others 1％ 造型・ 砂処理 6 . 8 ％

Percentage of Use Power (Power consumption)

[East Factory] Contract demand: 3000kW

[West Factory] Contract demand: 4500kW

Melting furnace 74%

Molding/ Sand treatment 13% Molding/ Sand treatment 6.8% Dust collector 6％ Compressor 3.2％ Processing machine 1.8％ Others 2.2%

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SLIDE 5

~ Energy-saving Operation~

Productivity Evaluation of Factory (Goal)

To set the volume of accepted product (kg/hr) as management target

(Production weight (kg) – Rejected weight (kg)) / Operating hours (hr)

To clarify about equipment capacity and target of each process To switch the operation mechanism from molding main operation to melting capacity main

  • peration.

☆How to get the maximum of equipment

capability?

【Target of Melting Process】

4000kg/h (Targeting 1000kg per tapping per 15min)

To targeting furnace operation without keeping warm by melting of leaving iron!

Melting work/min Electric current (Full

power)

Tapping Furnace charging Putting crane Control (TP, temp.

measuring)

Slag off

2 3 1 3 1 4 1 5 1 8 1 9 2 0 2 1 2 2 1 6 1 7 7 8 9 1 0 1 1 1 2 1 2 3 4 5 6 3 2 4 2 5 2 6 2 7 2 8 2 9

Melting of leaving iron by high-frequency induction furnace

Tapping 1000kg Material charge1000kg

Completing control at a time

3Ton 2Ton

Completing control at a time

~ East Factory

Concept of productivity improvement~

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SLIDE 6

Problems

  • Melting capacity cannot be demonstrated due to

variation in pouring weight.

  • Timing of a tapping call is not clear.
  • Certainty of quality governing of molten metal is required

(control at a time).

  • Re-checking of cycle time of the molding machine is

needed since it does not demonstrate the maximum

  • capability. (It follows the change of weight per flask.)

I mproving the above four problems!

Unstable Melting Operation due to Variation in Pouring Weight

Pouring weight Molding capacity Weight required Tapping weight Melting capacity Difference in melting capacity kg/flask flask/h kg/hr kg/tapping kg/hr kg/hr

1 5 1 6 2 4 6 4 1 6

Loss of melting heat- retention

2 5 1 6 4 1 4

Melting and molding: full

3 5 1 6 5 6 1 4 4

  • 1

6

Melting: full, molding: waiting for tapping Operation state

Leveling this variation to 1000kg is needed.

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SLIDE 7

2 1 7 . 5 ① 1 7 2 6 E 5 ③ 北 2 1 7 . 5 ① 8 2 6 ③ 1 7 2 6 ③ 1 8 2 6 E 5 ③

8 ：0

2 1 7 . 5 ① 1 7 2 7 ② 2 4 2 7 ② 北 1 2 1 7 . 5 ① 4 2 7 E 2 1 ② 北 9 1 6 2 8 E 1 1 9 2 8 E 1 北 9 2 1 7 . 5 6 4 1 ﾊﾝｶﾞー ① 南

7 ：0

出湯量 鋳込数 重量 製品名 位置 時間

Re-planning of Process to I ncrease Amount

  • f Molten I ron at Manufacturing Section

Target Tapping Weight 1000kg

Challenge for leveling of melting tapping weight I mproving Measures Against Load of Changing Mold

Using molds of casting small product

and large product in turns per tapping is required.

  • As for mold change of molding machine, two

molds can be set by adopting conventional shuttle type (manual operation). However, load is reduced by cylinder due to heavy burden for workers.

(But having approx. 20 seconds of molding loss as mold change)

Before leveling

  • f tapping

Approx. 20 taps/ day

Increasing Approx. 3 times After leveling

  • f tapping

Approx. 60 taps/ day

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SLIDE 8

出湯の呼び出しタイミングの明確化

出湯中

配湯空け替え中 出湯後 材料投入

ＭＥ Ｋ Ａ 自動 注湯機

大取鍋 待機中

密閉による温 度低下防止 蓋開けタ イ ミ ングに問題

注湯準備完了 溶解準備完了

Visualization of trouble point by standardization of melting, distributing, and pouring works

I mpact:

I mproving of Productivity and I ncreasing of Pouring Temperature

As a result of leveling, improving of productivity is

verified.

  • Productivity: 1558kg/h -> 1655kg/h (Approx. 6.2% up)

Furthermore, pouring temperature changes!

1410℃ 1380℃ 1360℃ 1330℃

Before leveling After leveling

Temperature increase of

  • approx. 30 degrees C. is verified.
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SLIDE 9

After leveling (Fading 15min)

Production weight: 20kg/flask Number of moldings: 47flask/charge Tapping weight: 950kg/chargeﾞ Final flask pouring temp.: 1350℃

Possible pouring time/ tap can be extended by temperature increase though it was 13 minutes before leveling

Before leveling (Fading 13min)

Production weight: 20kg/flask Number of moldings: 40flask/charge Tapping weight: 800kg/chargeﾞ Final flask pouring temp.: 1330℃

【TRY】Extending 2 min in possible pouring time

Effect of heat-retention in ladle and improvement of Mg yield by increase of processed molten metal

2 min extension determined Variation in Cycle Time of Molding Machine

Displaying cycle time in each process of molding-line

Shortening of cycle time and clarifying trouble point

Control of each process, stop time for molten metal waiting and the number of times of molding-line.

18.5 17.4 18.7 18.7 18.3 18.5 5.1 18.6 17.5 18.6 18.7 18.2 18.6 5.2

6 3 192 234 4 426 158 575 18.7 632 715

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SLIDE 10

Kaizen (I mproving) Activity for Problem Point

◆ H i s t

  • r

y

  • f

l i n e s t

  • p

p i n g

ラ イン停止日 ラ イン停 止年月 停止N

  • .

工程 コー ド 工程 停止 箇所 コー ド 停止箇所 停止区分 停 止 時 間 （ 分 ） 問題点 原因 対策 いつ誰が 直 2 1 / 3 / 1 51 3 2 2 2 A P S 2 反転機 チョ コ 停 1上枠反転②スリ ッ ウレタ ンローラ ーモータ ー芯だし 3 / 1 6 中田、 落合 2 2 1 / 3 / 1 51 3 2 4 2 A P S 4 枠合せ チョ コ 停 3枠合わせ時平ピン 平ピン側ブ ッ シュ に地金があり ピンと 噛みこ んだ 2 2 1 / 3 / 1 61 3 2 4 2 A P S 4 枠合せ チョ コ 停 5５ ０ ６ Ｌ Ｉ 上がり 不良 エアーバルブ が完全に開いていなかっ た為、 エア 2 2 1 / 3 / 1 61 3 2 2 2 A P S 2 反転機 チョ コ 停 1 0上枠反転②スリ ッ モータ ー芯だし を スプ リ ング調整実 3 / 1 6 岡本 2 2 1 / 3 / 1 81 3 2 8 2 A P S 8 枠入枠分離 チョ コ 停 1３ １ Ｐ Ｓ 、 ５ Ｃ Ｃ カ デグリ スが硬い 2 2 1 / 3 / 1 81 3 2 1 2 A P S 1 造型機 チョ コ 停 3型抜き不良多発 石綿フ ク ロ１ ５ ０ 2 2 1 / 3 / 1 81 3 2 6 2 A P S 6 N O 1 枠送り チョ コ 停 1Ｎ Ｏ １ Ｔ Ｒ 台車連結 ？ 割り ピン再セッ ト 3 / 1 8 中田 2 2 1 / 3 / 1 81 3 2 1 2 A P S 1 造型機 チョ コ 停 6盛枠原位置近接外 盛枠が多少動く 原位置近接５ ｍ3 / 1 8 中田 2 2 1 / 3 / 1 81 3 3 1 3 砂場 1 ﾐﾙ ド カ 停 6 0ミ ル排出ゲート Ｃ Ｙ Ｃ Ｙ Ｌ ク レビス部に 今後ピン等で固定し 回ら ないよ 2 2 1 / 3 / 1 91 3 2 1 2 A P S 1 造型機 チョ コ 停 1 3エアーレータ ーモー 振動が一番の原 溶接面サンダー 3 / 1 9 中田 2 2 1 / 3 / 2 31 3 2 7 2 A P S 7 N O 2 枠送り チョ コ 停 1 3４ Ｔ Ｒ 上で定盤ロー 定盤ローラ ー抜け 定盤ボルト 確認3 / 2 5 ボルト 確認 1 2 1 / 3 / 2 61 3 2 1 2 A P S 1 造型機 チョ コ 停 5スピルサンド ３ 過負 朝一砂出し 時ベベルト 状況確認造型者 1 2 1 / 3 / 2 61 3 2 2 2 A P S 2 反転機 チョ コ 停 2上型反転①ウレタ ローラ ー回転、 振 点検強化で対応 ４ 月教育時予定 1 2 1 / 3 / 2 91 3 2 8 2 A P S 8 枠入枠分離 チョ コ 停 1３ １ Ｐ Ｓ カ デンリ ュ ウ グリ スが硬い 2 2 1 / 3 / 3 01 3 2 8 2 A P S 8 枠入枠分離 チョ コ 停 1３ １ Ｐ Ｓ カ デンリ ュ ウ グリ ス硬い 2 2 1 / 4 / 51 4 2 1 2 A P S 1 造型機 チョ コ 停 3朝一上型砂抜け２ スク イ ズ圧不足？ 1 2 1 / 4 / 51 4 2 1 2 A P S 1 造型機 チョ コ 停 3１ １ Ｃ ２ ダルマスト ダルマＳ Ｔ 動きが 清掃後油塗付 落合 2 2 1 / 4 / 51 4 2 8 2 A P S 8 枠入枠分離 チョ コ 停 5６ ０ ６ Ｃ Ｌ エアーモレ Ｃ Ｙ Ｌ 取付配管が ２ 直操業時メ シ時 4 / 5 中田、 落合 2 2 1 / 4 / 51 4 2 1 2 A P S 1 造型機 チョ コ 停 5Ｐ Ｐ Ｊ １ ０ ０ 型落ち多 操業後上型レベレベリ ング確認 4 / 5 落合、 西川 2 2 1 / 4 / 61 4 2 5 2 A P S 5 重垂 チョ コ 停 1 1重り 確認近接不良 重り のズレにより 対策案検討中 1

Little improvement should be made when repairing

Certainty of Quality Governing of Molten Metal

  • Prevention from erroneous

input of returned materials

FCD450 FCD500 To put materials number on riser and runner To double check with materials indication of each palette

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SLIDE 11

’ ０ ９ 年度 ’ １ ０ 年度 ’ １ １ 年度 生産性（ k g / h ) 1 6 2 6 1 7 1 1 7 9 7 電力k w h / 出銑ｔ 5 7 3 5 6 8 5 5 4 5 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 6 1 5 1 5 5 1 6 1 6 5 1 7 1 7 5 1 8 1 8 5

生産性（ k g / h ) 電力k w h / 出銑ｔ

kwh/t Kg/h

Transition Graph I ndicating Productivity and Melting Consumption

【 Second half of FY】 Carry out leveling of tapping weight of molten metal

Review of cycle time of molding machine Kaizen (improving) activity for problem points FY2009 FY2010 FY2011

Productivity (kg/h)

Power kwh/tap t

・Targeting constantly full-power operation

・Continuing operation without stopping even in lunch-time. Operating hours: 7: 00 - 16：00 (1 shift 8hrs)

Electric energy per tapping weight March 18: 587.8kW/ t (Material change / Trial manufacture) March 29: 546.6kW/ t (No material change) March 12: 667.3kW/ t (Line trouble)

Graph I ndicating Demand Transition per Day in East Factory

Year: 2013 Operation start Preheating

  • peration
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SLIDE 12

~ Summary~

Electric furnace operation at the time of energy-saving operation

① Do not keep melting furnace warming, but tap

immediately after temperature rising!

② Do not cool ladle by increasing each tapping weight as

much as possible!

③ Make a system for working less line stops (equipment,

quality, trouble)!

④ Improve final yield rate (sprue cup, casting plan, leaving

iron, and reject, etc.)!

⑤ Do not stop lines even when taking a meal or break! ⑥ Increase tapping weights per day! Working in shifts. ⑦ Reconsider pre-heating operation! (electric furnace, ladle) ⑧ Check operating state daily and solve the problem

immediately!

Thank you very much for your kind attention.