Adds Spectro OES, 3D printing and new shotblasting machine to its capital equipment lineup.
“It might have taken us four years to be certified ISO 9001:2015 through SABS and it has been a long road but once you see that certificate framed and ready to display you feel very proud of the company and all of those that helped achieve the significant milestone in the company’s history,” said Greg Estman, Operations Director at Viking Foundry.
“It has required a considerable cash injection with each building and our manufacturing process and systems being upgraded.”
“Achieving the ISO 9001 standard is not about establishing a set of procedures that are complicated and difficult to manage. The aim is to provide a workable management system that is suitable for our organisation. With the right support and the knowledge of your employees, you will end up with a system that will improve all areas of your organisation,” continued Estman.
Quality Manager Johan Bekker with Operations Director Greg Estman holding the ISO 9001:2015 certificate
“Implementing an effective and robust ISO 9001 quality management system will help you to focus on the important areas of your business and improve efficiency. The management processes that are established throughout your business will provide a sound foundation, leading to increased productivity and profit. This in turn will improve your customer acquisition and retention,” said Estman.
“Certification to the ISO 9001 standard can enhance an organisation’s credibility by showing customers that its products and services meet expectations. In some instances or in some industries, certification is required or legally mandated. The certification process includes implementing the requirements of ISO 9001:2015 and then completing a successful registrar’s audit confirming the organisation meets those requirements.”
“Organisations use the ISO 9001:2015 standard to demonstrate the ability to consistently provide products and services that meet customer and regulatory requirements. It is the most popular standard in the ISO 9000 series and the only standard in the series to which organisations can certify.”
The new 3D printer that Viking Foundry has acquired
“ISO 9001:2015 compliance can substantially improve quality management systems and the bottom line. These days ISO 9001:2015 certification is the norm rather than the exception.”
“It took us a longer period than it normally takes because as you can imagine a foundry is not an easy place to audit. Additionally we had a number of personnel hiccups along the way which always set us back. We were finally audited and accredited in December 2020 but have only received the certificate and flag in May 2021.”
New capital equipment
“Because of the harshness of manufacturing in a foundry environment you constantly need to upgrade or replace your mechanical equipment. Last year we invested in a new hanger type shotblasting machine that can be loaded with up to one and a half tons of castings in a ‘Christmas Tree’ configuration and the castings can be of irregular shape and don’t all have to be the same type of casting. The castings are manually loaded and then transported via an overhead conveyor into and out of the chamber.”
The new hanger type shotblasting machine that can be loaded with up to one and a half tons of castings in a ‘Christmas Tree’ configuration and the castings can be of irregular shape and don’t all have to be the same type of casting
SpectroMAXx arc/spark OES metal analyser
“We have also invested in the eighth generation of its SpectroMAXx arc/spark OES analyser that has been improved with innovative new capabilities and advancements in performance to achieve fast, accurate elemental analysis precisely tuned for material control and foundry applications.”
“The SpectroMAXx may well be the industry’s leading OES line with more than 13 000 installations. The newest generation instrument features outstanding speed, quick and simple standardisation, reliable and accurate results, minimal gas consumption and a low cost of ownership for a more intelligent elemental analysis of incoming source materials, for in-process testing and traceability, and for final quality inspection.”
3D printer
“For many years now, many international foundries have regarded sand casting moulds and cores produced with a 3D printer as the standard. This is because those companies are based in countries or economic zones where they have the numbers to justify the investment. This technology is well established in the iron and metal casting field and is used wherever it is beneficial. While these applications primarily lie in the area of prototypes and small batches, the limits are increasingly shifting toward bigger and bigger volumes, as the performance of the 3D printing systems continues to improve.”
The new eighth generation SpectroMAXx arc/spark OES analyser
“With the increasing importance of additive manufacturing, 3D printing has established itself as a continuing trend. While the production of moulds for castings or prototypes can take several weeks or months, the printing process only takes one to two days, depending on the size of the component. Even the production of complex moulds is possible, which would otherwise be very time-consuming and costly in conventional metal casting. With the help of CAD data, complex geometries with undercuts can not only be freely designed, but also manufactured extremely accurately. This always ensures a high product quality and reduces rework. 3D printing also eliminates the need for moulds, saving foundries production cost and storage space.”
“A foundry that does not have a 3D printer at its disposal is actually throwing money away. We have invested in one and although it is early days, we are already seeing the benefits. We can print a master faster and more accurately for the patternshop.”
“With the shortage of skills and the reluctance of the younger generation wanting to find a career in our industry you are going to find that our industry is going to use the new technologies even more going forward.”
For further details contact Viking Foundry on TEL: 011 873 5093 or visit www.vikingfdy.co.za
