ARE YOU READY FOR THE FOUNDRY REVOLUTION?

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HERE IS THE LEAN MANUFACTURING

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If you are also a brilliant entrepreneur of a foundry regular as clockwork but your margins are getting lower…

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THERE IS A PROBLEM…

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You can’t stand comparison with the competition!

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Today in your foundry you have different standard die-casting cells as they always have been offered and for years you have been processing with cells assembled in this way: 

• Press
• Mold
• Lubrication system
• Stripping robot
• Die casting cooling system
• Bench

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Consequentely, your production happens as follows:

• You press the casting in your die-casting cells
• You put the pieces in a holding area
• You bring them to the deburring department
• You cut and deburr it
• You put the pieces in a holding area
• You bring them to the shotblast
• You pack and deliver them

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SO YOU OPTIMIZED SPACES AND LOTS
AND YOU THINK THAT YOU
CAN’T DO ANY BETTER

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You have organized all the spaces with signs to facilitate truck operators on the routes they have to follow in different areas of storage, thereby transforming your company into a supermarket with posters where you can find the bread and other products. The trucks turn around the factory like crazy loosing lots of time of your resources and especially of your production.

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YOUR ENGINEER TAKES CARE OF
INDUSTRIALIZATION AND BECOMES
A POSTER DESIGNER  PSYCHOLOGIST!

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He spends the day writing specific casting-finishes, then he designs big hangers for the factory and the remaining time he spends training the workers. When he is not doing this he wastes time speaking with clients about his production what he definitely isn’t able to produce.

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BUT THER IS A PROBLEM:

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EVERYTHING GOES AGAINST YOUR  PRODUCTION
THE CASTING QUALITY IS UNCERTAIN
AND IS NOT SO CONSISTANT!

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It is NOT the case if you have complicated die-casting and punching moduls. The ones you need immediately are skilled engineers able to intervene and manage unforeseen events and who can get on with production processing in the most efficient way. And you DON’T need engineers designing posters and wasting time…… AND YOU PAY THEM!

You are conscious that you DON’T have the workers as skilled as you would like to have and the nght is always too long…. often fatal.

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EVEN IF YOU WERE MERKEL YOU CAN’T
KNOW HOW MUCH THE CASTING COSTS

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Working in the way you are doing now, you have NO idea how much your die-castings cost:

• How much are the direct and indirect costs?
• How much does mold maintenance affect the cost?
• How much does storage affect the cost?
• How much does the cutting affect the cost?
• How much does the deburring affect the cost?

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YOU ONLY HAVE SO MANY PEOPLE
TO MANAGE, SO MANY SCRAPS
AND UNFORESEEN EVENTS

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Currently your production is organized with lots of storage and a lot of time waiting, in which you try or hope to plan production by considering the unforeseen events, even taking into account that you need to repair the mistakes of many people working on the production.

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BUT HOW MANY TIMES DID YOU NOTICE
THAT YOUR PRIECES ARE NOT CONFORMING,
EVEN AFTER HAVING TWO STORAGES FULL?

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The ones I’ve just described are common situations, which you can find in many foundries. The process was designed 50 years ago and nobody thought to change it. Every day I speak with entrepreneurs, like you, about the same problems. 

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ALL THIS IS NOT YOUR FAULT…
YOU ARE NOT ALONE!

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Today, everything has changed and after so many comparisons and so much experience with entrepreneurs like you, finally I have the solution that will revolutionize your business!

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ARE YOU READY
TO REVOLUTIONIZE YOUR FOUNDRY:
HERE IS THE LEAN MANUFACTURING

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I developed a series of machines that guarantee a flexible and lean production, making every step and speeding up the process thanks to LEAN MANUFACTURING.

LEAN MANUFACTURING used on systems gives immediate solutions like:

– Production time gain

– Saving money with fast and much easier processes.

– End client satisfaction and loyalty

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HUNDREDS OF PEOPLE IMPROVED THEIR
PROFIT MARGINS INSTALLING
THESE SYSTEMS, EVEN IF WE
THOUGHT IT WAS IMPOSSIBLE!

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Old Style Solution                                                 Trebi Solution with AFC50P machine

     

BEFORE & AFTER

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What we did together was to develop a series of machines that had to be installed in the die casting cell. In fact at the die-casting is added:

• AFC-P cutting and deburing machine
• Casting monitoring systems
• Shotblasting machine

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Your standard cell will not change, but we found a method and space to add a machine allowing you to finish the castings during the die-casting cycle.

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YOUR PRODUCTION PROCESS
WILL BE SIMPLIFIED AND
ENHANCED HERE’S HOW TO DO IT:

• The part is diecast
• It is cut, deburred, controlled and shotblasted before the operator gets it
• The operator checks the piece and puts it onto the pallet
• Your pieces are ready to be delivered

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If you are an entrepreneur who is conscious of the health of your foundry, then you can get a thousand benefits from this solution which will put  you back in competition with everyone else, and not only…

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WITH THIS SOLUTION YOU CAN
EVEN COMPETE WITH THE CHINESE

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The concept I explained is simple and looks even trivial now that I have described it. Do you think anyone can provide you with a cutting and deburring machine and the rest comes automatically… but you know nothing really happens like that.

I saw many improvised homemade machines, made “by the neigbor who is a great mechanic” and made by my competitor who can sell anything with an attractive price.

I really saw it with my own eyes and heard it with my own ears.

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IF YOU THINK YOU SAVE MONEY TRUSTING
IN “HOMEMADE” SOLUTIONS…

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… YOU WILL GET A COMPLEX
MACHINE TO USE

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These improvising mechanics  buy what they find on the market and try to make it work by assembling all that they find.

Maybe you also tried a machine of theirs and you had so much difficulty in producing your pieces.

I hope for you that it didn’t happen, because if it was the opposite….

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….THE CUTTING MACHINE WOULD
SLOW DOWN THE PRODUCTION CYCLE

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Today no one else shows you a machine which gives you:

• Reliability
• Continuity
• Moderate cycle time
• cutting of every kind of casting
• deburring in line with the cycle time

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The machine is integrated with other components and it interfaces with a shotblasting system.

This kind of machine is called AFC-P.,  in which we put a robot and a series of solutions allowing you to cut any kind of casting.

During the press-cycle the machine can do many things. In only a few seconds, you can have  casting ready for delivery with the certainty of no errors, managed at the same time by a minimum number of workers.

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Installing my solutions you will
have numerous advantages…

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With us:

• No more wasting money
• No more improvised solutions
• No more operators mistakes

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And then:

• A simple and lean production process
• You save space and human resources
• There will be less waste and more profit

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HOW LONG DO YOU WANT TO WAIT BEFORE
INVESTING FOR YOUR BUSINESS BENEFIT
AND START EARNING WHAT YOU DESERVE?

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Piercarlo Bonomi
The Main Expert in Robotic Cutting and Deburring Machines