Abstract
This paper deals with the optimization of the production process of vibrocasted refractory products. The main goal is to make efficient and automate the production of moulds for refractory blocks. A theoretical research was followed by an expert analysis of the current state of the manufacturing process at an industrial partner. The next step was to analyze complete portfolio of refractory vibrocasted products, which results in choosing a representative sample whose dimensions most correspond to majority of the moulds produced. Subsequently, a design was done, to make the production process more effective with respect to time, technology and construction aspects, focusing on increasing productivity, reducing human labour and increasing production modernization. In the end, the design options were evaluated in terms of time and cost, and the ideal process of the manufacturing production was recommended with respect to the latest technology. It includes a solution for material composition and optimized design of moulds for vibrocasted refractory materials to increase production efficiency moulds and cost reduction while maintaining mould accuracy and quality. These products are subject to high demands in terms of material quality and precision, and at the same time costly to produce due to manual manufacturing.
Highlights
The aforementioned shortcomings and reserves in possible procedures set out the requirements that should be used to increase work efficiency, reduce time requirements and ideally reduce current high material and human labour costs
It can be seen on the Gantt Diagram of Production Time-consuming (Fig. 1) that the mould making process takes up more than a third of the production time from the entire brick manufacturing process
Development and optimization activities can be divided into two stages: 1. Development of the material composition of the new type of mould 2
Summary
Mould production in the company does not have a solid workflow. Technological procedures are not processed and everything is based only on the experience and skills of the production workers. Conventional woodworking machines are used in production, making complex products difficult to produce and not with the necessary shape or geometric accuracy. The remaining dimensions can only be measured after casting the brick and the subsequent mould modification is much more complex. Production and systematization documentation is not in the best condition. The manufacturing division contacts the service division with the task of setting the price and deadline for production.
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