bruce s. phipps mpi incorporated · profit through innovation bruce s. phipps mpi incorporated ....
TRANSCRIPT
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Profit Through Innovation
Bruce S. Phipps MPI Incorporated
13th World Conference on Investment Casting
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Let’s take a look at wax room problems
Profit Through Innovation
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The solution:
Innovative Automation
Profit Through Innovation
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Why Automate?
Automation = Repeatability!
• Pattern to Pattern Repeatability • Assembly to Assembly Repeatability
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Why Automate?
20%
Patterns per assembly
25%
Casting to raw materials
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Why Automate?
Decrease casting defect rate
Decrease cycle time
50% 50% 50%
Decrease labor required
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Customer Results
INCREASED DECREASED INCREASED YIELDS SCRAP PROFITS + =
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Who can Automate?
• Small Parts long runs • Complicated High Value Assemblies • Companies ready to buy more Equipment
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Automation Experience:
Successful Automation Projects:
1. Automated Injection of Turbine Blades2. Automated the Assembly of DS and Single
Crystal Turbine Blades3. Automated Pattern Assembly
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Sharing Facts
Foundry Success Stories
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Example #1 Automating a Wax Injection Machine
• PROBLEM: – manual handling of wax pattern; greatest cause for
pattern to pattern variation – as much as 50% of the metal scrap
• SOLUTION: – automating the injection process
• RESULT: – much of variation eliminated
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Example #1 Automating a Wax Injection Machine
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Robotic Injection - Automation
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Customer Results
• Double the number of patterns injected per day • Pattern yields increased 10 to 20%
– Reduced pattern distortion – Reduced pattern defects – Uniform pattern trimming, minimal variation
• Higher casting yields
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Customer Results
INCREASED DECREASED INCREASED YIELDS SCRAP PROFITS + =
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Example #2: Automated Assembly of DS and Single Crystal
Turbine Blades
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Foundries’ Goals: Reduce costs and improve profits. Solution: Automate the wax assembly Result: Eliminate the variability that comes from manual assembly.
Example #2: Automated Assembly of DS and Single Crystal
Turbine Blades
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• Elimination of variation caused by use of extrusions.
• Elimination of variation caused by manual assembly of sub-assembly components.
• Grain selectors are assembled in the injection process.
Steps:
Example #2: Automated Assembly of DS and Single Crystal
Turbine Blades
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Robotic Assembly - Automation
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Robotic Assembly - Automation
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Robotic Assembly - Automation
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Robotic Assembly - Automation
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Example #2: Automated Assembly of DS and Single Crystal
Turbine Blades Results: • Extremely uniform and repeatable assemblies
• Increased strength of the wax assembly • Repeatability in Process
• A more uniform shell coverage due to accurate spacing • Improved thermal gradient of the final shell • Improved metallurgical properties • Higher casting yields • Decreased cycle times • Reduced labor
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Customer Results
INCREASED DECREASED INCREASED YIELDS SCRAP PROFITS + =
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Example #3 - Avalon Precision Casting Outsourced Automated Pattern and Assembly
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Example #3 - Avalon Precision Casting Outsourced Automated Pattern and Assembly
Avalon is a job shop foundry specializing in commercial and aerospace hardware components. I want to thank Avalon for allowing us share their name, and specifics.
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Example #3 - Avalon Precision Casting Outsourced Automated Pattern and Assembly
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Example #3 - Avalon Precision Casting Outsourced Automated Pattern and Assembly
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Outsourced Automated Pattern and Assembly
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Results:
15% 23% 28% 31%
Patterns per mold Metal yield
Outsourced Automated Pattern and Assembly
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“What was the one finger rule now is the one finger nail rule.”
Mel Kman
Unexpected benefit:
Outsourced Automated Pattern and Assembly
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1st Coat Outsourced Automated Pattern and Assembly
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2nd Coat Outsourced Automated Pattern and Assembly
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3rd Coat Outsourced Automated Pattern and Assembly
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4th Coat Outsourced Automated Pattern and Assembly
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5th Coat Outsourced Automated Pattern and Assembly
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5th Coat with Seal Coat Outsourced Automated Pattern and Assembly
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Customer Results
INCREASED DECREASED INCREASED YIELDS SCRAP PROFITS + =
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How can you approach Automation in your wax room?
• Be selective • Foundry Friendly Assembly • Partner with a proven innovator in Wax Room Automation
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Conclusion
Automation = Repeatability!
• Pattern to Pattern Repeatability • Assembly to Assembly Repeatability
Results:
• Decreased Casting Defects • Higher Casting Yields
• Reduced Operating Expense • Improved Safety
• Increased Customer Satisfaction
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Automating Your Wax Room
Significantly Greater Profits
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Questions?