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SANDMAN is about..

Reclaiming lost profits by reducing costly casting rejections , by

Organising, analysing, modelling and Leveraging a Foundry ’s green

sand data legacy by prescriptive and predictive process opt imisation

analytics; thereby enabling the User Foundry to move from reactive to

forward looking green sand control and management."

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What is the current scenario in green sand foundries?

What Foundries know? What Foundries need?

• Green sand properties used/measured over the period

• Various types of defects and rejection per part

• Required consumption of raw material for sand mould preparation

• How to utilize data of sand properties available with foundry

• What is the root cause of each rejection/defect

• What is the optimal values for each sand properties to be used/maintain to reduce rejection and access use

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Foundry historical data of various sand properties

measured e.g. Sand weight, Sand reuse, Bentonite, LCA etc.

Details of production per shift

Casting part properties e.g. weight, material etc.

Various rejection, casting defects observed per shift

or per part

Optimal values of sand properties to be used to reduce rejection/ defects

CpK Charts, Statistics of properties, Histogram,

Process capability charts

Heatmap – identify sand properties, responsible for major rejection/defects –suggest optimal value to avoid repetitive rejection

Rejection prediction

Powerful Algorithm with Mathematical Model

What is SandMan?

INPUT OUTPUT

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How SandMan Works?

Foundry - Upload sand properties data per shift or

day

SandMan - Identify sand properties value which has played major role in rejection, suggest optimal value for next production to reduce repetitive rejection/defects

SandMan – Display graphics of various rejection report, loss due to rejection

Foundry - Upload each system change, process change on

shift/daily basis

Foundry - Upload production, rejection, type of defects data

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Preserves User foundry’s data legacy by getting all foundrydata organised into one single, synchronised format

Foundries normally collect data at various points of generation. collating these datapoints requires a SOP discipline so that the updating of data is never compromised.Without this process all rejection analysis is incomplete and also inaccurate.

SANDMAN, by it’s functionality pre-requisite of data integrity, collation andsynchronisation; that the user foundry’s data is mandatorily updated to the latest data.

SANDMAN mandates that Date of:

• Sand parameters = rejection (before and after machining) = production (= heat code ; if the user foundry is able to collate)

•  by this process, data is analysable, with accuracy, withinrequirement.

minutes and seconds of

How SandMan Works?

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SandMan Features

• Login • Web based application access through given user-id and password

from anywhere 24X7 – No capex required in hardware• Saas (Software as a service) model

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• Dashboard overview • CEO/ COO/ Director Operations has a daily Dashboard update of all

the pivotal points of green and parameters and related casting defects as well as process control status - Rejection date wise, part wise, defect wise, petro component or defect wise • e.g. Blow hole foundry stage- 0.8%, 3.5% rejection on 23rd July

SandMan Features

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• Dashboard overview• Loss due to rejection date wise, for each production line

• e.g. INR 74,950 loss on 23rd July• Loss INR 17,400, defect - blow hole @ m/c stage on 23rd July

SandMan Features

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• Data Management• Data Upload – Provision to upload different sand category �les for

data visualization / reports and data analytics• Sample files provided by SandMAN in the required EXCEL

format

SandMan Features

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Keeping the foundry profile and variation data always‘on alert’ and Validated

The user profile and foundry configuration data sheets, combined with the

user definable variation limits

not only capture the foundry’s

it enables SANDMAN to use

on various parameters allows the program to

sand preparation equipment and capabilities,

the same for computational analysis control

limits on the foundry’s green sand properties on a personalised basis.

This configuration also form the basis for validating the data being

uploaded so that no incongruent data is recognised without

attention of the management.

the express

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• Data Management• Data storage – Provision to view uploaded history and raw

data of previous uploaded filles• The unique annotation feature, ensures that the foundry is the

owner of this data legacy without limitation in its lifetime

SandMan Features

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• Data Management• Annotations – Record various changes, events occurred on shop floor

during production and these will be visible in charts. e.g.• Increase bentonite to increase Active Clay 24 kgs setting • Sand recirculated

SandMan Features

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• Data Management• System changes – Record various system changes and these also

will be visible in the charts. For example,• Change in Machinary – Jolter valve changed• Change in Machinary - Ceramol Sprey started, 45 kg new sand

SandMan Features

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Preserves sand system experiential legacy

By means of the facility to annotate events and record system

changes

correlate

through the history of the user foundry, and, then

that to rejections and process variations; valuable

experiential legacy is passed on to successive managers

enablingavoiding costly repetitive mistakes, rejections and

repetition of proven process control towards low rejections.

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How SandMan Works?

• Data Management• General files – Upload/download to allow users to maintain arepository of files/reports and photographs.

• Surface quality result image file after increasing lusteron

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• Report• SPC Report – chart display the historical data of the selected

properties for the time period selected by the user..• line graphs are useful in studying the variations of any property

SandMan Features

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Reduces need for expert human interface in GreenSand management and control

The prescriptive and predictive trends give clear, data analytic based,

the user foundry needs toindication of the most optimal

maintain to achieve best levels

parameters

of rejection control.

The 'what if' functionality used

heat

in conjunction with the most significant

influencing parameters maps/mathematical models are a

powerful tool to examine various scenarios which the user would like

to model with his conventional domain wisdom.

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• Report• Comparative Report - Cp and Cpk are the process capability

indices that measure the capability of process in p roducing the outputs within the specified limits.

SandMan Features

Measurability and Statistical Process Control

•  Integration of Process Control Statistics, CpK tables,Histograms, box Charts, design of experiments andProcess capability Charts and Comparative

comparativeReportsanalysisadd powerful measurability and

between Annotations and Eventsexperiential legacy.

of the User Foundry’s

•  Never before has foundry data been so powerfully usedto control the process parameters and thereby achieve sustained repeatability of reducing casting defects.

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• Sand Analytics• High influences - The bar-chart results indicate the top 2 prepared

sand properties that have higher influence in rejec tion and needs to be modified to achieve the optimal rejection per centage

SandMan Features

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• Administration• Here all foundry related configuration is made. One of the main

feature in this section is the setting of alert. Pr esently the alert can be set for the following -• Model Built , Min/Max Violation, Erroneous records uploaded at

data entry stage.• Sum of all rejection type more than Total Sand Reje ction

Quantity• Rejection Quantity more than Production Quantity

• Annotation Added• System Change Added

SandMan Features

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Why SandMan?

• Wastage of energy • 1million tons of castings/yr x 1% rejection x 0.7MW electricity lost

= 70,000 MW loss per year.

• Reduce generation of toxic waste sand, dust collector dust pollution

• Improve foundry energy audit and green house gases (carbon footprint) audits in the inevitable near future.

• Achieve sustainable process consistency, reduction of related repetitive casting rejections using foundry’s own historical data using multidimensional rejection analysis across multiple parameters of green sand.

Brings 'cold/dead' data to life and adds powerful, forwardlooking vis-a-vis reactive decision making capability forreducing casting rejection and reclaiming lost profits!

•  with the design and use of complex and powerful mathematical models, the userfoundry is able to extrapolate and interpolate it’s historical data sets for

multidimensional rejection analysis across multi parameters of the green sand.

•  by this prescriptive and predictive analysis, process capabilities in the green sandpreparation process and it’s overall eco system are aimed to be achieved.

•  by achievement of sustainable process consistency, reduction of related repetitivecasting rejections is also possible.

•  This translates into reclaimed and sustainable profits for the user foundry in

significant and valuable amounts

Why SandMan?

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Sandman Highlights

• Preserves User foundry’s data legacy by getting organised into one single, synchronised format.

all foundry data

• No bias - All prescriptions and predictions are based on userfoundry's own data.

• Reduces need for expert human interface in Green Sandmanagement and control.

• Preserves sand system experiential legacy.

• Brings cold/dead data to ‘life’.

• A powerful Green sand Audit Tool.

• Keeping the foundry profile and variation dataValidated

always ‘on alert’ and

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What is ROI (Return of Investment) - SandMan?

Control your rejections because major Input costs are out of your control !!

Currency is in INR - feel free to change

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A powerful Green sand Audit Tool

The presence and application of SANDMAN in the user foundry can be a

powerful statement to their customer, of the user foundry’s process

capabilities to achieve sustainable levels of process control and thereby

over rejections and resultant environmental

impact.

and energy conservation

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For any further query contact us.Auto Design Online – Authorised distributor for SandMan (North-WestIndia region)

Email: info@auto-design-online.com

Mobile: +91-9824247774

Web: www.auto-design-online.com