How to Secure Best Results in Combining Hoisting Apparatus With Molding Equipment

By W. C. BRIGGS, New York

In preparing this paper, the writer's underlying thought has been to suggest a means for solving some of the difficult problems of foundrymen who are trying to systematize their work and costs; to assist in placing the work in the foundry in the hands of the man who will produce the largest tonnage of any particular class of work; to aid in the difficult problem found especially in jobbing foundries of trying to make castings from patterns from which only a few castings are required on molding machines; and also to distribute the work in the foundry where the crane or hoist facilities are best suited for handling the work.

Foundries can be divided into at least four distinct types, namely, gray iron, malleable iron, steel and bronze and aluminum. Each type can be classified into a number of types based on the size and kind of castings made. Many foundries of each classification may make castings of a similar character continuously. Even in this class of foundry the system outlined in this paper can be applied with some degree of helpfulness.

It is a comparatively simple matter for engineers to design and lay out a foundry to make the same kind of work continuously. The scheme outlined is intended to suggest methods that will assist the larger number of foundrymen who make a variety of sizes and weight of castings.

Labor is Big Problem in Foundry

The question of labor cost is more and more becoming a big problem with all foundrymen and exists from the time the raw materials arrive until the finished castings are loaded. In order to reduce the number of common laborers

to a minimum, designers give entirely too much consideration to the handling of raw materials, loading of castings, etc., where the total pro rata cost per ton is a much smaller factor than the skilled workman's time on the molding floor.

This, of course, is not true in all cases, but is apt to be true in the case of the jobbing foundry where the owner or engineer has in most cases failed to find a means for making a layout of the foundry with foundry floors, cranes, hoists and molding machines so combined that they are adapted to handle to the greatest advantage a predetermined class of work.

If, however, each pattern when received is placed in a definite classification as outlined in the following table it will be possible to use hand molding and hand lift where it can be used with the highest efficiency, and hand molding and crane equipment where it will be more efficient, and likewise machine molding and hand lift where these factors can be combined to produce the largest tonnage.

4-HMHL 4--HMCL 4-MMHL 4-MMCL 5-HMHL 5-HMCL 5-MMHL 5-MMCL 6-HMHL 6-HMCL 6-MMHL 6-MMCL 7-HMHL 7--HMCL 7-MMHL 7-MMCL 8-HMHL 8-HMCL 8-MMHL 8-MMCL 9-HMHL 9-HMCL 9-MMHL 9-MMCL 10--HMHL 10-HMCL 10-MMHL 10-MMCL 11-HMHL 11-HMCL 11-MMHL 11-MMCL 12-HMHL 12-HMCL 12-MMHL 12-MMCL 13-HMHL 13-HMCL 13-MMHL 13-MMCL 14-HMHL 14--HMCL 14-MMHL 14-MMCL

Tag Patterns According to Classification

The writer has not intended to carry this classification into all the sizes of flasks or depths of cope and drag that some foundries no doubt find it advisable to classify, but sufficient to outline the general scheme. The plan proposed is to place this classification list in the hands of the patternmaker or the man who has charge of the flasks so that suit

FIG

1-THE WORK NOW HANDLED BY THIS CRANE FORMERLY WAS HANDLED BY A JIB CRANE. PRODUCTION WAS INCREASED 4 TIMES BY THE USE OF THE CRANE SHOWN

able tags or stencilled markings may be applied to the pat

tern.

Tonnage of castings is very largely influenced by the ratio between the size of the flask and the weight of the casting and the cost of molding follows in much the same ratio. Therefore with a system of this kind, the matter of setting the price is simplified. For instance, if a casting weighing 50 pounds is produced in classification No. 1, the same casting produced in class No. 2 would cost more, and by keeping the cost of castings made by each classification, a table soon could be prepared that would be of great assistance in estimating the cost of making all kinds of castings.

Size of Flask Influences Cost

Of course there are many other elements that enter into the cost, but most of these elements do not influence the price anything like the ratio between the size of flask, which governs the amount of labor to a large extent. It is realized that green sand and dry sand molding costs vary, and that the kind and size of cores are important elements.

These classifications also will help to solve the cost problem which has been found so difficult in foundries turning out a large variety of work. It is a well known fact that there is a limited amount of foot pounds of work for every man. It varies somewhat with the man, but just as sure as a man's energies are properly applied, just as sure will he produce more and better results. If it is necessary for a molder to go to the pattern loft or flask shop to get his pattern and then to select or fit up a flask or assist the pattern maker or flask man to do so, and then get his floor ready, cut up his sand, find the necessary rigging, gagers, etc., he is not going to get started to make his job with as much dispatch as he would if a system was used whereby these factors were taken care of in a systematic way. There may be some work that can be rammed by hand or by treading in with the feet at as low a cost as can be done by any other method, but such jobs are few and far between and a good skilled mechanic should never be used for that kind of work.