General Foundry Management

Every foundry should be concerned about increasing productivity of each process and reduction of related costs. For this purpose, it needs to study all facets of its operations; processes and equipments establish best principles and reach optimum utilization of recourses. The general foundry management will need to study all aspects starting from building layout and design, transportation, scrap, yield, raw material, production scheduling etc.

Building Layout : - The first step in general foundry management should start with a study of how well the building space is being utilized and what changes can be brought about. The building should provide for easy passage to and from the complex for workforce, vehicles and equipments. It should provide a good environment to workforce with enough ventilation, light, sans dampness, proper storage for raw materials. Planning should be done for proper placement of exhausts, probable expansion in future and dust removal.

Transport Systems : - Next a study of transportation system being used should be managed. All vehicles should be kept in proper shape and regularly serviced. Routes should be planned in such a way that various jobs can be clubbed. For a new plant, it should be studied if the plant has easy access to roads, railways etc.

Drawing Up Design Of Cast : - The process of drawing up the design should ensure the best possible mould design, for production of high quality of casting. This process should be done in least possible time and cost and give the maximum output from the given resources. The design should study the casting and technology used for making the casting.

Production Scheduling : - The production scheduling should be done in a manner that some processes can be shifted to times when demand for power is least in order to avoid peak hour penalty. Also, maintenance processes can be conducted in weekdays so that premium charges of power can be reduced and cheaper weekend rates can be utilized. Employees can be given a share in cost saving by way of reduced wastage and better productivity. Better control over various processes should be exercised.

Increasing Yield : - This can be done by better casting processes. It helps increase profitability and reduce wastage in form of raw material, workforce, power, and resultant increase in per unit output.

Handling Scrap : - Scrap is the residue left after various processes, but is not always a waste. Any foundry with a good management setup, not only tries to minimize scrap, but also tries to extract the maximum possible usable material from scrap. It can also be sold to outside processes or internal scrap may be used in foundry's own processes.

Planning For Change : - Change management means, studying opportunities for up gradation or improvements in existing processes and equipments, planning for such changes and efficient implementation of the required modification. This will include a study of the costs for bringing about the required change.

Periodic Maintainance Of Plant And Equipment : - it is very necessary that the plant and equipment maintenance should be done from time to time and not only at the time of any breakdown. This will not only help avoid delay penalty, shutdown costs, but also help upkeep the foundry's good position in front of the customers.

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