Software solutions

One route through the foundry.

Each part’s routing links the departments: core making, molding, melting, fettling, heat treatment.

Foundry processes

One route.
Every department.

01Core shop

Core jobs on your core machines — counted in shots and cavities.

CASCULATE puts every core job on a core machine and a day, shows how full each machine is — and turns the shots your operators report into good cores. The cavities of each core box are part of the plan.

Core shooters with daily utilization and the core jobs planned on each day, with their progress

02Molding

Pattern plates into flasks — on the molding line and in hand molding.

CASCULATE puts pattern plates from several orders into one flask — one material only — and recommends how many flasks to make. Melting sees the tonnes as soon as the flask is released.

Flask with plates from three orders, 11 of 12 area units used, 5 flasks recommended, pouring temperature 1420 °C

03Melting

Melt charges per furnace — filled from the molds you release.

Pouring orders come straight from molding, hand molding and continuous casting — with material, tonnes and pouring temperature. CASCULATE puts them into charges per furnace. No charge is filled beyond its furnace.

Charges on two furnaces over three days, in gray and ductile iron, with tonnes and pouring orders

04Fettling

Fettling stations with their own capacity — start and finish reported at the station.

Every order that is molded already has its fettling job. CASCULATE plans it on your stations, day by day — with each station’s own output. The fettling shop sees its work before the castings arrive.

Workstation table with type, status, performance in parts per hour and active flag

05Heat treatment

Furnace batches by program and temperature, filled up to what the furnace holds.

CASCULATE groups heat treatment jobs into furnace batches — same day, same furnace, same program, same holding temperature from the routing. Each batch is filled up to what the furnace holds.

Batches on an annealing furnace: stress relief at 600 °C, quench and temper at 850 °C, normalizing at 920 °C, each with tonnes and utilization

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What is possible for your foundry.

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