The Tupy foundry in Saltillo, Mexico, has implemented a system-wide product-tracking capability developed by SinterCast AB, capable of following the production progress for cores, molds, and castings through to the shipping stage. It’s the first foundry in the world to adopt the SinterCast Cast Tracker system for high-volume series production, the developer noted.
“The SinterCast Cast Tracker technology is an important step in our commitment to establish Tupy as the cast iron foundry leader for process control, innovation and Industry 4.0 traceability,” stated Fernando de Rizzo, president and CEO.
SinterCast is primarily known as the developer of a process control system for compacted graphite iron production. The Cast Tracker is applicable to all grades of iron produced at Tupy Saltillo, include CGI, gray iron, and ductile iron.
Tupy manufactures automotive engine blocks and cylinder heads at foundries in Joinville and Mauá, Brazil, and in Saltillo and Ramos Arizpe, Mexico. It is among the highest-volume CGI producers in the world, and a licensee of the SinterCast CGI process.
Tupy Saltillo’s use of the Cast Tracker™ technology follows an eight-month validation period. The technology involves labelling every core package and optical camera recognition of the core package in storage and during molding. Then, it uses RFID identification of every flask during molding, casting and shakeout to establish complete traceability throughout production.
As described by the developer, SinterCast Cast Tracker elevates castings from commodity parts produced in batches to individual components with complete and unique traceability of the production history.
“The technology ensures that every core package is within specification prior to casting, and generates a single database to allow engineers and managers to improve process efficiency, and to troubleshoot the foundry process, identifying and eliminating the root cause of casting defects,” according to its announcement.
“Together with the SinterCast Ladle Tracker® technology that we pioneered in 2016, Cast Tracker ensures that every ladle and every core package remain within our process limits, while the comprehensive database improves our internal measurement of process efficiency KPIs, troubleshooting and traceability,” de Rizzo continued. “With the Cast Tracker technology, our customers will know the exact minute the core package was produced, the storage time, the liquid metal history, the shakeout time, and all of the quality control inspection results for every casting. Cast Tracker brings improved quality and efficiency for Tupy and improved confidence for our customers.”