SOP’s

For the batch production, the foundries will need to go through these processes.

1. Arrangement Time
When we receive the order, we will discuss with the production dept., so they will check when
they could start the production for particular PO. Normally, the molding machines will be busy
for the existed orders, all orders need to queue up.
For this process, normally, 10 to 20 days will be needed. If the order is very urgent, we may
arrange it to jump the queue, so to shorten this waiting time. However, this is only for urgent
situation. All clients are important for us.
If the orders are continuous, or clients could give us a demand plan, then this process will
become unnecessary, because we could arrange the production schedule in advance.
2. Molding Time
For the shell molding process, we need to use molding machines to produce the sand shells and
cores, which could be called as sand molds. For the lost wax investment casting process, we need
to make wax molds. For the moulding machine process, also known as the green sand molding
process, sometimes, we need to make some sand cores too.
For this process, normally, 7 days will be needed. If the order quantity is large, our workers will
keep making the sand molds, these existed sand molds will be moved to the next process.
3. Metal Melting and Cooling
After the sand molds completed, we will use electric furnace to melt the pig iron with alloys, or
melt steel materials, then pour the melted metals into the sand molds for iron castings, or pour
the steel into treated wax molds for steel castings.
The melting process is very short. We could melt 30 tons metals each day. The liquid metals will
stay in the sand molds or wax molds, till cooled naturally.
4. Sand Blasting and Grinding
After the cooling process, we will use sand blasting equipment to clean the sand residue on the
metal castings, then we will grind the castings to remove the extra materials, parting lines, gating
heads etc., then do the second sand blasting again.
Grinding castings is very hard and dirty works, so all foundries are facing the shortage of skilled
grinding workers now. Therefore, this process will need some days.
5. Machining Process (if necessary)
After cleaning process, if the castings need further machining works, then we will move the
castings to our machining workshop.
It is difficult to say how many days will it take, because it will depend on the machining
complexity.
6. Painting and Coating Time
If the castings need painting, hot dip galvanizing, powder coating etc., then we will move them
to the professional coating workshops in our local. We could do the spray painting in our
foundry, but we have to entrust the other coating works to the professional coating workshops.
Normally, the spray painting will take some time, because it will need time to be dry, but for
other coatings, the time will be shorter.
7. Quality Inspection and Packing Time
We will do some quality inspection during production, but after all works completed, our
inspectors will do the final quality inspection, including all dimensional inspection, material and
defects inspection. After quality inspection, we will pack the casting products for delivery.
Normally, the quality inspection will need 1 to 3 days depends on the result of sampling
inspection.