Green sand control in a metalcasting facility relies on reducing the variation in key measurable aspects of sand properties. All metalcasting facilities make good sand at times and bad sand at times. Successful plants make good sand most of the time.
Reducing variation in green sand systems consists of determining the key independent variables, finding a method to quantify current variation and implementing improvements to reduce variation and monitor the results.
Grede-St. Cloud, a green sand molding operation producing iron castings, operates two molding lines, each with its own sand system. For each line, daily tests are used to quantify variation within the sand system and make corrections as needed to keep within the optimal performance range.