Hapman Presents Case Study on Automated Transfer Process

The Challenge

Manually shoveling sand to fill cope and drag boxes 

(casting flask) for sand casting is a physically demanding 

process for mold makers, who on average shovel 20 tons 

of casting sand weighing 100 lbs. per cubic foot into 70-80 

molds per day. This demanding operating condition creates 

a high level of physical strain on the mold maker’s body. 

The result of this strain was a multi-million-dollar-per-year 

workers compensation obligation for an aluminum foundry. 

The financial impact not only hit the company’s bottom 

line but slowed overall worker efficiency. Company leaders 

knew that keeping workers safe and healthy was not only 

important for their people and profits but also for their 

customers. They knew if they could improve productivity 

through process improvements, they could reduce lead 

times and improve customer satisfaction, which in turn 

would continue to grow their business. After many searches 

on Google and conversations with various material-

handling companies, foundry management discovered 

Hapman.