Questionaire

Quest. 1: Have you already carried out process optimisation with regard to material efficiency in your foundry?

This question concerns the following

yes, we are continuously working on increasing our metal yield
new trends have been recognised but implementation is rather difficult
customers occasionally have proposed modifications
our processes have not been changed for years
no

Quest. 2: Are you working on a continuous reduction of the energy deployment in your foundry operation? help

This question concerns the following

The melting of metal and the holding of molten metal make up a substantial part of the energy consumption of a foundry. In many foundries, more energy is consumed to keep the metal in a molten state, as in the actual melting process.
In addition, significant amounts of energy are consumed in other areas than the metal provisioning. Foundries are as large consumers of compressed air. Other large energy consumers are likely high pressure die casting machines, which mainly hydraulic parts are also electrically operated. Sand and mould foundries can use hot core manufacturing processes, such as mask core and hot-box cores, that use gas or electricity for heating the boxes. The heating of die cast moulds, pans and oven linings may account for a significant part of total energy consumption.
The data from two foundry examples show, that the remaining foundry processes - except the melting and holding - are responsible for almost half of the energy consumption of a foundry. This includes activities with motors and drive equipment, compressed air, lighting, space heating and boiler systems. Energy efficiency measures should capture both areas - smelter and remainig processes. [UBA GI (2004). S. 263]

yes
no, but we know of our energy deployment
no

Quest. 3: Do you regularly reduce the reject and reworking rates in your production? help

This question concerns the following

Rework means all measures that are executed on a defective product, so a salable state is reached. Causes of rework consist for example in insufficient production documents, in unsafe manufacturing processes, improper handling of materials, components and products in manufacturing or transportation or inadequate packing.

yes, the reject rate is very low and we hardly ever require reworking
no, but we are aware of the rejection and reworking rates
the rejection and reworking rate is only improved when we introduce technical innovations
no, but we carry out reworking very thoroughly

Quest. 4: Do you avoid or reduce wastes in your foundry works?

This question concerns the following

yes, the entire process and the selection of all substances used have been optimised with regard to waste avoidance
we have an internal recycling system for scrap and sand
our wastes are processed by third parties
there are no active waste avoidance measures in our processes

Quest. 5: Do you reduce the quantity of waste sand during sand mould casting to a minimum? help

This question concerns the following

Since foundries use sand intensively as inert base, the regeneration of sand is an essential aspect to consider the environmental impact. Environmental benefits and cost savings resulting from a reduction in the amount of sand to be deposited and the consumption of new primary sand [UBA GI (2004). S. 275].

we regenerate used sand for internal reutilisation
used sand is externally reutilised
no
does not apply

Quest. 6: Are you working on a continuous reduction of waste water creation in your foundry?

This question concerns the following

yes, minimisation of water consumption and multiple usage and recycling of process water are integral components of our process technology
no, but the subject has been recognised as a savings potential
no, but we use an extremely large wastewater treatment plant
no

Quest. 7: Do you already ensure that treatment is environmentally and raw material-friendly when storing your raw materials? help

This question concerns the following

An environmentally friendly and resource-saving material storage includes the avoidance of soil and water contamination and the optimization of internal scrap circuits.

yes, storage and storage management for all raw and auxiliary materials comply with the latest standards
the quality of the warehouse stock is regularly checked
storage conditions for raw and auxiliary materials play a secondary role; our core competence is casting

Quest. 8: How are improvements in the process sequences in your company accepted and implemented by the staff? How does information exchange between the product development, manufacturing, engineering services and purchasing departments take place?

This question concerns the following

there are interdepartmental staff meetings which regularly follow technical developments and optimise process sequences
product or project-based meetings take place in which staff are informed of new processes
there is no cross-departmental exchange of views

statistic data

Number of your employees

your industrial sector

your main business sector:

Hinweis