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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