Lean manufacturing of cast iron products

Foundry casting, one of many metal production processes, can produce complex shapes that are difficult or expensive to make with other processes. Molten metal is poured into a mould of the desired shape, allowed to cool and then removed for further processing as needed.

A large consortium of 14 partners from 5 EU countries has launched the EU-funded project FLEXICAST (Robust, and flexible cast iron manufacturing) to transform the conventional (batch-by-batch) foundry process into a flexible (mould-by-mould) process.

The team is exploiting principles of lean manufacturing in which machines are grouped in manufacturing cells according to the parts or products they produce. Such cells improve efficiency by creating short, focused paths in a small physical space. They can also reduce scrap and reworking because problems can be discovered close to the process creating them.

Scientists are taking advantage of advances in melting technologies and automation. Sensors and other instrumentation will be integrated for monitoring the quality of the cast iron produced. Integration of an artificial intelligence-based control system that analyses chemical and microstructural data will have major impact. A robot cell will accomplish automated finishing processes.

The team has delivered a detailed design of the cast iron manufacturing cell, and most of the equipment and instrumentation is in an advanced state of design and commissioning. Over 100 test cast specimens have been prepared as well. Numerical models are supporting the design and optimisation work.

The technology will be showcased in a demonstration pilot plant in real industrial settings. It is expected to reduce energy consumption by at least 30 %, enhance melting temperature consistency during moulding, reduce overheating, and minimise defects and scrapped parts.

FLEXICAST is implementing lean manufacturing practices in a cast iron manufacturing cell with advances in heating and pouring technologies and computerised automatic control. Life-cycle assessment will ensure that technology increases the competitive edge of EU SME foundries in a sustainable way. Results will be formalised in guidelines and potentially support European standardisation in the field.