Driving the Digital Transformation in Metal Casting Operations
We have mentioned many times that ancient traditions carried forward by generations and huge amounts of experience may be replaced by modern state-of-the-art software solution technologies, making the industry attractive to young talent, providing room for legacy renewal and helping to rejuvenate. This article # 6 shall highlight the importance of what it means to bring the operations on ONE standard platform, how DATA can be visualized using dashboard and other instruments, e.g. FIS (foundry information system) and why classical systems including Excel/ERP are continuing to fail in foundry environments. After all, we want to transform the industry into something technically and IT wise advanced as we cannot change the way castings are done BUT we can change the way castings processes are controlled using easy to use and plug & play software-based solutions.
FRP – Foundry Resource Planning Solutions, were introduced, one year ago to the FOUNDRY magazine readership and India wide audience. Many people and industry experts contacted the editors and asked many questions. Among the questions asked ONE stood out and we want to answer this in an elaborated way:
HOW MUCH DOES IT COST AND CAN I AFFORD IT???
The editors realized that the industry is ripe for something that is innovative, new in terms of capabilities and ultimately really works in metal casting environments. Foundries are known for the complexity of juggling man-machine-material combined with organizing core-melt-mold-fettling-machining and much more. Standard disposition tools and Excel files using manual means of reporting are the current reason of WHY foundry is not transparent and the majority of operations do not succeed in having “fewer headaches” – so to speak.
We mentioned many times that foundry Managers of the future become IT – gurus as many computer-based technologies must be mastered in parallel, it is not enough just to know about methods and casting.
One example of today’s foundry world is the collection and interactive usage of PRODUCTION DATA in an integrated system. Foundries using generic systems or only Excel always struggle to get their own production under control by precisely knowing what is where / when and how. Numerous examples, especially from the jobbing foundry world, can be mentioned upon demand.
- In EDITION 1 of this series we introduced FRP and where it comes from, looking back at 30+ years of development with over 300+ installations and foundry projects realized. It was highlighted that a foundry is not an undefined “Enterprise” as we focus exclusively on them since they have significantly different corporate processes compared to standard ERP systems users – this has led to the abbreviation FRP or Foundry Resource Planning solution technology, taking care of ALL foundry specific processes from inquiry to delivery of castings, including PPC and Scheduling.
Many times Software companies consider a foundry as another common enterprise. But make no mistake – a “Foundry” is not a common enterprise. Its processes are very unique, as no other industrial branch in this business line actually creates things and provides final shapes from a liquid. The process of casting determines all the mechanical properties all the other industries will work with later on. Primary shaping is the task, and FRP the only tool capable to manage the process.
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In EDITION 1 of this series we introduced FRP and where it comes from, looking back at 30+ years of development with over 300+ installations and foundry projects realized. It was highlighted that a foundry is not an undefined “Enterprise” as we focus exclusively on them since they have significantly different corporate processes compared to standard ERP systems users – this has led to the abbreviation FRP or Foundry Resource Planning solution technology, taking care of ALL foundry specific processes from inquiry to delivery of castings, including PPC and Scheduling.
Many times Software companies consider a foundry as another common enterprise. But make no mistake – a “Foundry” is not a common enterprise. Its processes are very unique, as no other industrial branch in this business line actually creates things and provides final shapes from a liquid. The process of casting determines all the mechanical properties all the other industries will work with later on. Primary shaping is the task, and FRP the only tool capable to manage the process.
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In EDITION 2 of this series we explained the CORE of the FRP® solution focusing on Planning & Calculation using a dedicated Resource Plan. Product and Resource planning using the resource plan is at the heart of the FRP system but it can also be a useful tool on its own if you want to calculate something quickly. Compared to other systems the FRP solution does not separate the work plan (or scheduler) from the parts list (BOM) but aligns itself with the way the foundry really works. All the resources needed to manufacture a certain cast part are displayed within a tree structure in a multi-step resources plan. It doesn’t matter whether it involves self-produced materials (cores, models, melt), purchased items (filters/feeders, sand, external services) or services (molding, cleaning, finishing). This makes it easier to duplicate and change parts, create new parts or, for example, to update changed bought-in materials for several products. The resource plan functions as the heart of the FRP® solution and provides the answers to almost anything the foundry operations wants to achieve.
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In EDITION 3 of this series we focused on WHY classical systems based on Excel / ERP fail in foundries as many foundries that have the desire to improve are still relying upon “old school” methods via MS-Excel and/or own customized ERP solutions and/or no ERP at all. As such, they fail in the edition 2 mentioned (incomplete list) of tasks to create reliability based on technology and facts rather than reliability based on human skills to improvise and overcome any obstacles.
We also explained why is, for example, MS-Excel (can be extended to any generic ERP solution) actually NO solution at all when it comes to foundry resource planning, please remember the foundry is no common enterprise and it is the only industry sector that creates and is shaping a product from a liquid and has both continuous and very much discontinuous processes in the same workplace.
We provided a comprehensive comparison between integrated FRP® and Excel/ERP.
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In EDITION 4 of this series we informed the audience on HOW they can achieve a kind of “foundry 4.0” level in 5 easy steps and we repeat the extract from that publication:
To understand FOUNDRY 4.0 we have to make sure it is understood that it is not equivalent to Industry 4.0. A foundry is a special place and we cannot copy general ideas as we must adapt to foundry specific solutions. Sometimes processes and structures to achieve 3.0 (maybe 3.5) must be created before the next step can be followed. E.g. IT – Infrastructure must be there! (STEP 1). However the „digital transformation“ is a (long) journey at times and the main question is and will always remain: How good is the quality of DATA? (STEP 2)
Any human interactions must be considered since many processes are executed still very much manually. As such foundries should consider that investments into hardware (machinery etc.) should coincide with investments into software solutions as well, where many neglect the potential they have. In the case of FRP®, it is that it is the forefront of a „foundry 4.0“ because of the standard platform it provides and can be used very easily on daily basis. In our case the benefits are very much obvious: Digital Transformation of foundry means clear implementation of FRP® with PPC and MES levels under considerations of other state-of-the-art technologies (STEP 3). In order to do that each foundry must exercise an isolation of individual problems, e.g. Scheduling of Man-Material-Machine (STEP 4). Subsequently, they are in the process of creations of individual CPC – islands that are integrated into leading corporate systems. Ultimately we look at an integration of Software + Man and Machine and Material in a homogeneous manufacturing system (STEP 5).
- In EDITION 5 of this series the key-point and most important aspect in making the foundries into something technically and IT wise advanced and making them into a modern high-tech enterprise that’s fun to work in and attracting young talent, is very much the exposure to standard systems. Imagine the worker on the core shooting machine has a computer screen next to him, he operates the core shooting machines, produces the cores and after every 10 pieces put on a tray he scan’s the barcode and press “enter” on a keyboard so that the system knows “10 pieces of good cores for client XYZ have been produced”. In return, the operator knows the status of the overall order i.e. the casting. Through an integrated feedback system with clear display icons on the monitor, he can check the quality of his work contributing to the positive outcome
Now coming back let us look at the answer to the most asked question. For example, if a foundry wants to know their KPI’s = Key Performance Indicators – and these can be manifold – then they have to ensure they have correct DATA from all available sources. Once KPI’s are defined, e.g. delivery reliability vs. production capacity and utilization then it’s simply about the correctness of the data. This data is through the previously described FRP® functionalities and WIP – work in progress feedback chains available. Internally build integration tests and functionalities are ensuring that this data is consistent. Build in loop-holes in the software will alert a user if the data is inconsistent or outright wrong.
From there it’s only a mouse click or two that are required to visualize this data inadequate format. Figure 1 is displaying 2 examples of data visualization of typical foundry KPI’s. Here RFQ’s are compared to time and location and in addition shipment of castings are compared on quarterly basis and destination. The “dashboard” that is displaying this data is highly customizable so that any person participating in the FPR® system can have his or her individual “KPI” displayed if required in REAL-TIME.
Can you imagine you have all these foundry details available at your fingertip, it’s reliable and accurate to the point and he looks at it on a daily basis 24 x 7? How much would it be worth to invest in order to have that? Is a single outright purchase enough? Is the organization – that has to carry the data collection details and discipline – actually in place? Ultimately what’s more important, making money on castings and knowing in detail about it OR being able to trace a casting without tediously looking at the shop-floor to ask all concerned where is my casting?
As it can be seen the REAL answer in today’s world of digitalization of workplaces is not to ask the question “how much does it cost and can I afford it?” the real question should be “how much will it cost me NOT to do it?” (i.e. introducing a standard FRP® system) and in addition “how long do I want to live with the fact that the foundry operations are NOT transparent enough to understand if we make or lose money on a casting after the post-calculation has been done.”
In summary: DIGITAL CONTROL + COST TO CAST + TRANSPARENT OPERATIONS + EVOLVE ON ONE STANDARD DIGITAL PLATFORM will be the future of metal casting operation.
