1 Fettling the most ignored operation in Foundries Prashant Mestry Mahindra & Mahindra, Automotive Division, C omponent D evelopment & M aterials M anagement, Special Process, Casting Commodity AD Annex Building, Kandivali, Mumbai 400101 e-mail: mestry.prashant @mahindra.com Keywords – Casting Fettling, cleaning operation Abstract – We in Mahindra and Mahindra do lot of casting development required for making different automobiles vehicles. In most of the Indian foundries fettling is not important activity and hence not given much attention. Every year we face acute shortage of castings from April to Jun and all the castings suppliers give a common reason that less manpower due to labour on leave. In some of the part the labour goes for farm harvesting during rainy session as they get more money and that job also is not as dirty as fettling. The casting supplier does not know how much business he has lost and how much we lost in these months. This is every year’s story, no improvements so far. Most of our Indian foundries they think that fettling is outsource activity; if the contractor is having big place and manpower then he is qualifying for doing fettling. Very few foundries are having procedure for fettling, what to grind, how much to grind is based on experience of that individual operator. The small automation like horizontal milling machine if they put grinding wheel in place of milling cutter then it can grind two faces at a time. This type of m/c is called as “Snag Grinders”. With such automation productivity increases as well as consistence in grinding so no rejection due to excess grinding. There are fully automated machines where once the program done the machine take care of all operation and complete fettled castings comes out, only the operator is required to do small work inside cavities. With this paper my intention is to motivate casting supplier to do good fettling which operator will enjoy, will take less efforts, and keep good surroundings and environment. Fettling in Non-Automated foundries Foundry process designer take lot of efforts to design pattern, core boxes and other tools, process and then we get casting like after nine month a mother deliver a child. How much efforts she take during nine months that only she knows, in same way efforts taken by designer and making the first casting he only knows that. After pouring when casting come for cleaning. Fettling department can give good face or bad face to the first sample. Most of the time fettler does not know which area to grind or remove and wrong operation start right from first sample casting, and then re- sampling starts. Hear are our foundries differing from foundries out of India. They will make all fettling arrangements before they make casting and so no chance for mistake,
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Fettling the most ignored operation in Foundries -latestfoundryinfo-india.org/images/pdf/TS-1B-IV.pdf · Fettling the most ignored operation in Foundries Prashant Mestry Mahindra
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