1. Process management control
In order to achieve this goal, we need a complete set of processes and equipment. All equipment serves the process, and the process required for any production process must be controlled. Machinery factories in developed countries have formulated strict control scope for all projects that have been proved to need control in production in science and technology, and where they can control.
Raw materials are strictly inspected and controlled, including the composition and specifications of various metallic and non-metallic materials. The parameters in the process are also strictly controlled, such as the compactness, wet strength, dry strength, moisture, crushing index, permeability, effective clay content, volatile matter, loss on ignition, dead clay content, temperature, sand mold hardness, etc. of green sand. Many domestic foundry manufacturers do not detect the effective clay content. The content of dead clay in molding sand is high, so the moisture content is high.
2. Selection and matching of instruments and equipment
In order to achieve the goal of control, there must be corresponding equipment and instruments. Electric furnace smelting or duplex smelting is adopted, and the carbon content is detected by carbon determinator, and the remaining dozen components are detected by spectrometer. If there is no electric furnace smelting and spectrometer rapid analysis, foreign customers generally will not buy your products. The spheroidization rate is tested by diamond polishing paste, and the sample quality is close to the photographic level; The depth of white mouth shall be checked with a sample plate; The mechanical properties can be accurately measured by the equipment configured by microcomputer; The casting samples are inspected by the three coordinate inspection table; The cleaned castings shall be inspected with special measuring tools and fixtures. Each process has original documents.
3. Quality management
Due to the complexity of the production process, no matter how advanced the quality certification is, no matter how good the management is, no matter how strict the implementation is, it is inevitable that waste products will appear. The problem is the attitude towards waste products. What a good quality system says is that everyone is a quality officer, and never let a waste product slip through the net from his own hands, never let a waste product leave the factory, and there will be no phenomenon of shoddy products being replaced by good ones. International quality certification (IS09000) and various special certifications are very strict, and fraud is not allowed. The inspection of quality certification is not whether there is a problem, but whether there is credibility. Problems can be solved and improved to meet the requirements of certification. If you cheat, you will lose credibility and will not be certified. Developed countries rarely see foundry manufacturers have any special treatment for certification units and personnel, and there is rarely fraud. Even so, some customers also stipulate that a third party must be present to witness the mechanical property inspection and jointly fill in the mechanical property inspection report, which shows that their requirements are strict.