(Thanks to Foundry Management and Technology for this post May 7, 2016 by G. Srivastava and R.C. Kothari.)
Part 2 of 4.
You’ll be surprised to learn how much commonality exists between the circumstances of a farmer and a foundryman.
We invite you to spend a few minutes on a journey through the past and present, to prove to you that farmers and foundrymen are very much alike, and that each merits every consideration for easy and assured availability of resources and respect. To justify this we have deliberated closely on similarities between their two different avocations, with the purpose of persuading foundrymen, and to add a moment of levity to the otherwise a dry routine of challenges we face every day. We hope it will bring some amusement to you, too.
Mr. Srivastava and Mr. Kothari are both degreed professionals at work in the foundry industry in India.
"Earth is there so kind, that you just tickle her with a hoe, she laughs with a harvest." — Douglas William Jerrold
In farming the end product is revealed in the harvest. The farmer keeps a watch on the progress of the crop, and values his effort on the quality and quantity of the harvest. If the harvest is abundant, he is happy; otherwise, he goes into debt, and depression. His efforts have failed.
Inspection and evaluation
In a similar manner, the foundryman evaluates his cast product at the knockout stage. A preliminary investigation and finding of any undesirable weakness in the casting is looked upon seriously, and action plan is drawn out to avoid its recurrence in next batch. The volume of the operation plays a big role in the viability of both efforts. More acreage in farming and more tonnage per unit of time in a foundry will enhance the economic advantages in both cases.
Inconsistency and unpredictability …
Both endeavors have a dominating feature of inconsistency and unpredictability to achieved success. This is due to a surprising collection of variables, a good number of these being independent to each other.
… the damage may have been done
While analyzing the mishaps and failures, one can easily get to the root cause of what went wrong and what remedial action got ignored somehow or was it totally incomprehensible. However, the damage has been done during the active process, and any corrective action can be made applicable in next batch of production only.
Product quality requirements …
While some of the as-specified quality requirements for farming and foundry products reasonable and justifiable for the characteristics they must possess (according to application), there are innumerable cases of requirements on that are totally irrelevant in the use of the finished product. These are standards imposed by buyers, and some are guided by wholly illogical, ignorant, or whimsical attitudes. For example, buyers may prefer round smooth potatoes, though in almost all uses these products are used in ways for which roundness and smoothness have no relevance.
Needed, or not needed
Similarly in the case of castings, instances of high quality requirements like very high dimensional tolerances, close to even rough machined surfaces, which may not be needed in usage, making the castings costlier. The buyers impose upon foundries some of the radiographic tests and standards for acceptance, details that may not matter to the products’ user. These conditions are attainable at a cost, and the buyer and producer must agree in order to establish the real minimum requirements.
Yet to be discovered
"What is a weed? A plant whose virtues have not yet been discovered." — Ralph Waldo Emerson
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