Methodology and implementation of controls in foundry

The quality demanded of industrial products requires companies to implement an effective control policy. The products obtained by all foundry processes obey this rule, all the more so as their use is widespread in most industrial sectors (transport, energy, etc.). To ensure that the parts produced meet customer specifications, the foundry industry relies on the latest scientific and technical advances in production process control and monitoring. Controls thus contribute directly to better control of production processes, with the aim of reducing scrap to a minimum.

However, foundries, no more than other techniques, can only supply perfect, defect-free products. It is important to clearly agree with the customer on the severity of the inspection methods to be used, depending on the functions performed by the part, its production cost and the agreed deadlines. Furthermore, the nature of the alloy, the foundry technique used and the type of production (unit or series) will all influence the inspection policy to be adopted. For the foundryman, the drafting of an inspection program defining the various procedures to be followed will be an essential aid to the production of quality castings, and, for the customer, the assurance of a progressive approach.

Finally, responsibility for inspection operations must be entrusted to qualified personnel who, in the case of inspection of parts involving personal safety, have accreditations and certifications specific to the inspection equipment used. Ongoing training and regular qualification checks guarantee the expertise of the operators appointed to carry out these inspections.

The aim of this article is to present the general principles, methodology and implementation of controls within a foundry, covering the entire foundry process (cast alloy, production process, traceability, etc.). The aim here is to describe the steps involved in setting up a global control methodology that will form the basis of a foundry's quality policy. The aim of this article is to enable the reader to design an effective control policy, adapted to the foundry process and agreed with the customer, so that it can be integrated into the part specifications. It should also make the reader aware of the need to draw up a control program, and of the balance to be struck between quality and over-control, so as not to harm the foundry's overall productivity.