Sandman is about reclaiming lost profits by reducing costly casting rejections, by organising, analysing, modelling and leveraging a Foundry's green sand data legacy through prescriptive and predictive analytics and process optimisation capabilities; thereby enabling the User Foundry to move from reactive to forward looking green sand control and management. Sandman is a unique, world-class software conceived, created and developed by Mr. Deepak Chowdhary, Founder of MPM Pvt. Ltd. and an experienced foundry person with over 30 years of hands on knowledge of the Green sand system and its dynamics. It's a first of its kind software in the field of Molding sand practice, and offers a solution which enables foundries to organize, analyse, model and leverage their greensand data legacy through prescriptive and predictive analytics and process optimization capabilities. Sandman thus, gives a foundry the ability to reclaim lost profits by reducing sand related casting rejections by moving from reactive to forward looking molding sand control and management.
In these times of fast changing economic scenarios, business eco-systems & the resultant increasing pressure on business sustainability; castings rejections and their control in molding sand foundries assume a huge dimension of cost and potential saving.
Back-of-the-envelop calculation indicate, the net cost of a 1% molding sand rejection in a 2000 ton/month foundry, in India, is approx.: 1.2 (INR 12 Million) to 1.5 crores (INR 15 Million) per annum.
Auto manufacturers are increasingly demanding that foundries reduce costs and improve sustainable productivity by reducing casting rejections to PPM levels, improve surface quality of castings and finished components, reduce emissions, reduce carbon footprints and comply with International foundry toxic waste disposal regulations and laws.
With increasing pressure on business sustainability therefore, casting rejections and their control in sand foundries assume a pivotal role in optimization of operational costs.
Times have changed. There is an increasing gap between domain experienced personnel and new, skilled manpower to manage the molding sand molding process which has always been known as an 'art'.
The element of the human interface in this process management is also becoming increasingly limited, as the process grows faster, more exact and increasingly dependent on fast depleting, standardization resistant, natural resources like silica sand, carbonaceous additives and bentonite.
As people age, change, move on, the legacy of the experience and knowledge of the foundry sand process and management is often lost or available only in limited spots to the succeeding controllers.
The transition often has no documented experiential legacy to pass on in a seamless manner, leading to costly, repetitive mistakes.
Foundry sand and related rejection Data is often recorded in nonstandard formats making even data retrieval and analytical capabilities, difficult. Data is often just a collection of thousands and millions of 'cold' data points which beg to be made meaningful as they are the treasure trove of the foundry analytics for profit if mined properly.4. Huge data points : Beyond Human Processing capabilities = reactive actions
As the volume of data becomes huge, even the most experienced sand manager cannot be expected to keep an all encompassing perspective and precise experience over a huge process and multi parameter variable scenario.5. Variability = Cost
To add to this process limiting situation, changes in supply sources, suppliers, machines, production environments, etc., add to the variability manifold.
Variability is often directly proportional to rejections. Costly, Rejections, Validation of any change is almost always at huge cost to the foundry.
Serious costs can occur because the effects are felt in the long term and correction logic is often mired in the variables of the interim duration of the change.
It hurts the foundry, immensely.
In its current iteration Sandman acts as a repository of the experiential knowledge of the foundry, with the ability to record, monitor and perform retrospective analyses on any process operation affecting the sand system2. Predictive Analytics:
It also has a feature-rich set of modules providing predictive and planning capabilities to foundry personnel, allowing them to optimize their operations through our analytics, enabling them to resurrect their otherwise dead data.
The power of multi-parameter, multi-variant analysis enables the foundry to detect and analyse the deviant and/or aberrant process parameters of the greensand, over any specified time period.
It also analyses various rejection incidences vis-a-vis the most influencing green sand paramter, thus allowing the foundry to take timely corrective actions to bring about process consistency
The Dashboard feature designed for senior managers and management, gives a complete overview of the foundry's state of the system sand rejections, causes and solutions, all in a few clicksIt also has a feature-rich set of modules providing predictive and planning capabilities to foundry personnel, allowing them to optimize their operations through our analytics, enabling them to resurrect their otherwise dead data The power of multi-parameter, multi-variant analysis enables the foundry to detect and analyse the deviant and/or aberrant process parameters of the greensand, over any specified time period. It also analyses various rejection incidences vis-à-vis the most influencing green sand paramter, thus allowing the foundry to take timely corrective actions to bring about process consistency4. Environmental Impact:
And finally, in addition to the benefits on the bottom-line of a Foundry, Sandman also helps in sustainable Environmental and Energy Star impact as reduced casting rejections contribute towards
- Reduced wastage of electrical energy
- Reduced carbon generation
- Reduced toxic waste generation by reducing used sand disposal
- Conserving scarce mineral products like Silica Sand, Bentonite and water