Palmer Mixer

Palmer Mixer

Spokane Industries has replaced an Omco batch mixer (50# batches) with a new continuous mixer that will enhance our coring abilities.  In light of the size of the castings we are making currently, the quality of the cores will improve dramatically.  With our previous sand system, we had to mix in 50# batches at a time, which can potentially create layers of sand that have subtle variations in strength.  With our new core system, we will have continuous feed and consistent sand pours that will eliminate this variable.

The new Palmer Mixer allows us to move more efficiently into the realm of a 2 sand feeding system that allows either silica sand or specialty sand.

Additionally, we are moving away from spraying the cores – which lacks consistency from operator to operator – to “flow coating” - which creates a more consistent wash coating and allows for greater material penetration.  These 2 processes are expected to greatly enhance our efficiencies and minimize scrap and waste.

With this new addition we are taking the opportunity to redesign the floor plan of the coring department, which will allow for less material handling, less wasted movement and greater productivity.

New Palmer Mixer Installation

Quench Filtration

Quench Filtration

Our engineering staff has conducted an in-house research project to ascertain the efficiency of filtered water in our quench tanks as opposed to the current quench tank usage, which recycled the same water repeatedly.  The results were quite compelling.  It was discovered that the cleaner the water, the better the properties attained in the quenching process.  Cleaner water creates a “more severe” quench – facilitating more consistent and predictable results, allowing for a tighter tolerance band for our mechanical testing. 

This filtration system with it’s $18K price tag more than pays for itself by eliminating the need to test and dispose of quench water on an annual basis while at the same time delivering more consistent and reproducible results. 

New Quench Filtration System

New Air Compressor Installation

Bldg. #4 air compressor

Consistent air pressure is a constant need in a foundry, and we struggle with a shortage of air from time to time.   The need for compressed air is driven by several departments, most notably the molding and finishing departments.  A shortage of air can affect mold quality, productivity, and efficiency throughout the production process. 

While we recognize that sales orders are below capacity, we are taking a pro-active approach to building infrastructure for future potential, understanding that we want to be prepared for the next wave of opportunity.

Adding a new air compressor serves this philosophy in 2 ways.  First, we are able to maintain consistent air pressure throughout the plant at all times; second, this gives us the opportunity to improve our finishing capabilities by 30%.

New Ingersoll Rand Compressor

Digital Controls

Reconfiguring Finishing Cells

Finishing Cells

In everything we do, we try to increase efficiencies, improve processes, and reduce waste.  There are 7 forms of waste; the 2 main forms of waste that most significantly affect our finishing department are over processing and wasted motion. In theory, just by moving operations into a certain area, you’re not really eliminating a lot of waste.  Effective cells are designed to eliminate those wastes.  We want to take “families” of parts and run them through a condensed work area designed for those castings. 

The introduction of finishing cells will also assist as we train new employees.  When we bring people onto the work force, they are somewhat isolated.  Being new, they wade into the unknown.  With finishing cells, you have teams.  The newcomer not only gets training but they become part of something.  They’re part of a team - part of something bigger than themselves.  They experience camaraderie that allows an outsider to become an insider very quickly. 

As a job shop, we have a wide variety of products that we process through the finishing department that would need to be identified and classified.  If we can identify similarities – alloy, size range, processing steps, etc.  We can process those in the same area and have the same people working on them that know exactly what work content is needed – no more and no less – to get that product out the door.  This would greatly enhance workflow and minimize waste.

At this time, the reconfiguration of the finishing cells is underway and the first iteration should be complete by mid-august.