Foundry Industry
Workforce Productivity Improvement
Primary Outcome35% Manpower Optimisation
Business Challenge
Heavy casting foundry suffered from high contract headcount dependency, manual flask handling delays, and poor spatial layout.
Client Situation & Operational Bottlenecks:
- •High contract labor dependency causing high conversion cost inflation
- •Heavy manual lifting of moulding flasks resulting in worker fatigue and injuries
- •40% non-value-added movement due to disorganized sand moulding and pouring bays
- •Uneven mould setting cycle times leading to molten metal cooling losses
Our Approach
- Executed Day-In-The-Life-Of (DILO) studies for moulding crews and furnace teams
- Mapped worker travel paths and ergonomics using motion economy principles
- Designed low-cost pneumatic hoists and gravity chutes for flask handling (LCIA)
- Redesigned moulding shop layout into cellular work bays by casting weight
- Created standardized work sheets for core setting and mould assembly
Key Improvement Initiatives
- 1Relocated core setting stations adjacent to moulding bays to eliminate travel
- 2Installed pneumatic assist hoists for effortless flask lifting and closing
- 3Rebalanced moulding crew sizes from 8 to 5 operators per bay
- 4Deployed Daily Management Systems with shift handover KPI scorecards
Before vs. After Operational Metrics
| Metric | Before Transformation | After Transformation | Quantified Impact |
|---|---|---|---|
| Mould Shop Headcount | 180 operators | 117 operators | -35% |
| Casting Output / Operator-Hr | 0.45 MT | 0.72 MT | +60% |
| Mould Assembly Time | 45 min | 28 min | -37% |
“
The industrial engineering work and low-cost hoists transformed our foundry floor. We reduced contract headcount by 35% while increasing casting output.
— Plant Head, Automotive Casting Foundry
KEY RESULTS
35%Manpower Optimised
60%Casting Output / Operator
37%Mould Cycle Time Cut
Services Delivered
- Industrial Engineering
- Manpower Optimisation
- Low Cost Automation (LCIA)
- Factory Layout Optimisation
- Standardized Work
Methodologies Used
Industrial EngineeringMOSTLow Cost Automation5SKaizenErgonomics
Service Capability
Industrial Engineering
Scientific time-and-motion analysis to optimize work content, ergonomics, and productivity.
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