How to become a high-quality precision casting manufacturer

Today, we will discuss in detail how to learn from the management of developed countries and become a high-quality precision casting manufacturer. The main characteristics of casting management in developed countries are: multiple process control projects, standardized and detailed process management, and strict quantification of control scope; Execute the process without compromise; Emphasizing development and creativity, continuously developing high-tech castings with higher intangible value.

1. There are multiple process management and control projects, with standardized and detailed process management and strict quantification of scope

The goal of casting production is to achieve high efficiency, low cost, and produce castings with qualified and consistent quality. Quality qualification refers to the castings having qualified dimensions, no surface or internal defects, and the material properties meeting the requirements. Consistent quality refers to the same performance and quality of each batch of castings as well as different batches of castings, with good consistency.

1.1 Process management control

To achieve this goal, a complete set of processes and equipment is required. All equipment serves the process, and the required processes for each production process must be controlled. Developed country foundries have established strict control ranges for projects that have been proven to require control in production through scientific and technological means, and for areas that can be controlled. The raw materials undergo strict inspection and control, including the composition and specifications of various metallic and non-metallic materials. The various parameters in the process are also strictly controlled. For example, European non-ferrous metal and high-temperature alloy foundries are not allowed to change the testing and control parameters without the consent of the competent department. In addition, there are original file records for the execution of each process, and the original file records cannot be changed arbitrarily.

1.2 Selection and matching of instruments and equipment

In order to achieve the control objectives, corresponding equipment and instruments must be available. Using electric furnace melting or dual melting, and using a carbon analyzer to detect the carbon content, and a spectrometer to detect the remaining dozen or so components. If there is no electric furnace melting and rapid analysis by spectrometer, foreign customers generally will not purchase your products. The spheroidization rate test uses diamond polishing paste to prepare samples, and the sample quality is close to the level of photography; Check the depth of the white mouth with a template; The mechanical properties can be accurately measured using equipment configured with microcomputers, such as tensile strength and yield strength; The casting samples are inspected using a three coordinate inspection platform; The cleaned castings are inspected using specialized measuring tools and fixtures. Each process has original document records. Using ultrasound to inspect spheroidization rate and internal defects, X-ray inspection of surface cracks. The coupling agent used for inspection is specifically designed for inspecting castings.

In order to achieve high efficiency and low energy consumption in production, the arrangement of production shifts should strive to ensure continuous production and reduce material and energy consumption. For example, enterprises that adopt a dual connection of cupola and electric furnace are arranged to work 12 hours per shift, 4 days a week. The process also needs to consider the convenience, safety, and high efficiency of worker operation. For example, the wax molds used to produce high-temperature alloy precision castings are light green, which protects vision and is beneficial for production; Choose the appropriate height for cleaning the workbench in the construction department.

1.3 Quality Management

Due to the complexity of the production process, even with advanced quality certification, good management, and strict execution, it is inevitable that waste products will occur. The problem is the attitude towards waste. A good quality system means that everyone is a quality officer, and we will never let any waste pass through our own hands, never let any waste leave the factory, and there will be no phenomenon of substandard products being replaced by good ones. International Quality Certification (IS09000) and various special certifications are not allowed to be falsified. The inspection of quality certification is not about whether there are problems, but about whether there is credibility. If there are any issues, efforts and improvements can be made to meet the certification requirements. If you engage in fraud, you will lose credibility and will not be certified. Developed countries rarely see foundry manufacturers treating certification units and personnel with special treatment, and there are also few instances of fraud. Even so, some clients require a third party to be present to witness the mechanical performance inspection and jointly fill out the mechanical performance inspection report, which shows their strict requirements.

Wherever instruments and tools can be used for control, they should be used for control. All instruments and meters are regularly inspected, calibrated, and recorded.

In order to achieve high productivity, the configuration and management of equipment need to be systematic and complementary. Many European and American companies do not have advanced equipment, but they have good compatibility and high reliability. This reduces the time lost due to a malfunction of a certain equipment causing the entire production line to shut down, and also enables the entire equipment system to meet the requirements for producing high-quality castings. There are many domestic manufacturers, many of which have advanced equipment, but some of them are poor, unreliable, and have poor equipment compatibility. For example, many domestic foundries do not have coordinate inspection benches and other advanced testing equipment, resulting in even if good castings are produced, there is not enough testing equipment and data to support their product quality. European and American companies also have strong maintenance teams.

Some colleagues in the technical and management departments of domestic casting enterprises are concerned that such strict process regulations and their strict implementation may cause production stoppages, affect production rhythm, and affect productivity due to problems in a certain link. In developed countries, there have been no production interruptions or productivity impacts caused by strict process regulations and their strict implementation.

In fact, loose process regulations and insufficiently strict process regulations cannot improve productivity, but are harmful to the improvement of productivity and product quality. On the contrary, it is precisely because of such strict and meticulous process regulations and execution that the energy consumption of castings in developed countries is much lower than that in China, while labor productivity and total output value are much higher than those of Chinese foundries.

A German foundry produces as cast low-temperature high impact toughness ductile iron through strict process management system, without the need for heat treatment. The attached test bar and casting body meet all the mechanical performance requirements of low-temperature and high toughness ductile iron. It can be said that optimized process procedures and strict implementation are actually the fundamental reason, or in other words, the key, for the entire industrial system of developed countries to continuously produce high-quality products.

1.4 Personnel Training and Job Setting

Cultivate personnel with a focus on practical results, and cultivate what is needed. The main methods include training courses (industry training courses, university training courses), and mentoring between old and new employees. The training is targeted and practical. Training is not a diploma, not a certificate, only for the needs of work.

If a process can be completed by machinery, it will never involve human labor; A position requires one person, never two people. For example, in a foundry, one worker is responsible for the sand treatment system of two wet sand production lines, responsible for all feeding, coal powder, new sand, water, etc., checking and controlling the performance of the sand, recording data, and also responsible for sample organization; A dedicated person is responsible for inspecting the cleaning workshop, including marking inspection samples, casting size inspection, ultrasonic inspection of spheroidization rate, internal defects X-ray detection of surface cracks, management of inspection tool library, etc.

2. Strictly implement the process

Craftsmanship is regarded as the production law of enterprises. Once a process is established, everyone from workers to management and technical personnel is responsible for executing the process. Although the workers have a low level of education, their quality in executing the process is not low, and it is feasible to implement the process regulations. If the process conditions are not met, workers cannot proceed with the operation. For example, if the temperature and composition of the molten metal are not up to standard, the furnace worker cannot come out of the furnace; If the temperature of the molten metal inside the package exceeds the specified pouring temperature range, the pouring worker cannot proceed with pouring; Would rather be poured into ingots; Products with unqualified hardness, size, and surface quality will not be released.

Equipment, raw materials, etc. are all designed to serve the process. For example, the spheroidization rate of ductile iron is tested by polishing with diamond polishing paste, and the sample quality is close to the level of photography; The dimensional inspection of casting samples adopts a three coordinate inspection platform, and other advanced detection equipment is used to inspect internal defects, Samples such as X-ray and ultrasonic testing are essential.

3. Emphasis on development and creativity, developing high-tech castings with higher intangible value

Foundries in developed countries have been striving to improve customer service in recent years, actively participating in the development, design, and production of high-tech castings, as well as high profit castings with higher added value. In recent years, due to the continuous improvement of the properties of cast metal materials, the improvement of casting methods, and the emergence of new casting methods, new development opportunities have been provided for new castings and casting design. Some metal castings have also replaced plastic shell components.

The Smith foundry in Minneapolis in the United States has replaced the originally designed track drive wheel assembled from 84 steel parts with a single ADI drive wheel casting, reducing weight by 15% and cost by 55%. Users save $190000 in costs annually. Compared to the original assembly parts, it saves 30 minutes of assembly time, improves wear resistance, and has a more aesthetically pleasing appearance.

It can be seen that casting design has great potential, and the design, innovation, and improvement of castings are endless.

Many foundries in Europe and America are collaborating with users to design, innovate, and improve castings. Some companies have more than ten such projects every year. As the above examples illustrate, the main work of developing new castings using new processes and new alloy materials is currently achieved through a combination of casting factories and users. However, developed countries have already seen companies specializing in casting design. These emerging companies use computer solidification simulation technology and computer casting design technology to combine with casting users and manufacturers to accelerate the development of new castings.

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