There are too many reasons to list but PS Auto Grinding, suppliers of market leading Koyama Automatic Grinding Machines, is experiencing record sales across Europe, Russia and Turkey and Foundries are stating the same main reason in most, if not all sales;Finding and keeping workers for grinding is becoming almost impossible.PS Auto Grinding notes that this is a trend across most regions with both higher cost Western markets and lower cost Central European, Russian and Turkish markets stating the problems of getting labour.Grinding departments are known as 3D, Dirty Dusty and Dangerous.In 2014 it appears that there are cleaner, less back breaking options in the service sectors that are as well paid and more attractive.Also, as price competition is fierce from customers and quality demands relentless there is enormous pressure to meet and exceed targets daily just to keep up with production.
+ Outsourcing companies have to add a profit margin. Manual grinding costs are already double in most cases than foundries grinding with Koyama machines so become much higher with additional outsourcers margin + logistics costs.Q. Why do outsourcing grinding companies not offer Grinding Services with Koyama machines, offering a faster, better service to foundries at a lower cost?
The Turkish market is the fastest growing market for PS Auto Grinding Limited in the European zone. In the last six months of 2013, this market added 8 Koyama machines in total. 2013 was a good year, if not brilliant, for Turkish foundries and the Turkish market still enjoys low but rising wages in comparison to Western foundries.There are Government initiatives to move foundries out of major cities such as Istanbul, Izmir, and Ankara etc. for environmental reasons, to free land for residential and commercial development. Also a rapidly educating workforce is looking for more white collar and higher paid work. The end result almost in all foundries is bottlenecks in grinding due to lack of workers willing to do this work.Take Atik Metal, of Izmir. They have one of the newest and most advanced foundries in Europe and a machining operation to match nearby.Extremely efficient melting, pouring, moulding, core making etc. all lead to higher productivity, more castings produced. Higher capacity meant seeking new customers for castings throughout Europe.Knowing that they would not keep up with production with manual grinding and keen to avoid the costs and logistics of using Grinding outsourcers they have just placed order for their 4th Koyama machine, due to arrive and be installed soon.Not only is this eliminating bottlenecks it is also having a very positive effect on machining as well because castings are ground to the same accuracy every time guaranteed without over grinding or under grinding.Result is a grinding department that matches the efficiency of the rest of the foundry.Highly efficient machines, 3 to 4 times faster than any manual grinder 24/7, that are very reliable with low running costsSimple to program, edit and operateLabour requirements are very low (I machine replaces 3 men) and conditions are now clean and safe as grinding is totally enclosed. This is a job that workers want and will stay with AtikCastings are no longer lying in foundry but are ground, then painted and machined ready for despatch and invoicing
Paul Smith, Managing Director of PS Auto Grinding Limited, Distributors of Koyama Automatic Grinding Machines throughout the European zone says;To be competitive PS Auto Grinding has to increase sales, reduce costs continually, and maintain necessary cash for the business. When I visit foundries I often see large amounts of manual labour working in dirty and dusty conditions and continually see bottlenecks, it makes we wonder.He continues. Why does a foundry in 2014 strive to find the cash to pay usually 3, 4 or 5 times more workers than foundries with Koyama machines, have castings unground that are producing no revenue, and require working capital to maintain until they are processed?In fact, foundries with Koyama machines cannot even be classed as grinding departments. The castings are loaded into the machines and the operators time is mainly on inspection and any slight hand grinding that is required. Result; faster output, better quality, time to invoice is faster and none of the cycle of rejection from quality that is evident in most manual grinding foundries.Finally, he adds PS Auto Grinding has been talking to foundries for years and asking them to view Koyama machines as a Labour Saving project and not a traditional foundry investment such as melting or moulding equipment. We would not run our office without computers, we could if we wanted, as we would need more people and do a bad job. We would also not delay the purchase of computers as the savings would start to pay back immediately, and we will have other benefits. Running a manual grinding operation needs more people, which results in more cash to find monthly, and results in a bad job in comparisonIt now seems that a lot of foundries agree with our viewpoint and a lot of sales are now funded by leasing. Delaying doing something about grinding gives no benefit, as most foundries see that sooner or later they will have to automate grinding to stay competitive. Leasing needs little capital outlay, payments and interest are funded by savings with a surplus, and payback, often less than 2 years, starts immediately.
Foundries report that Koyama Machines are on average 4 times faster than Hand Grinders Turkey is the fastest growing foundry market in the greater European area for PS Auto Grinding Limited, distributors of Koyama Automatic Grinding Machines.Leading Turkish foundry, Atik Metal of Izmir, have 4 machines, 2 for castings up to 50KG and 2 for castings up to 150KG.Murat Atik, Member of the Board of Atik Metal, puts it quite clearly;Why spend Millions on the latest foundry equipment to only produce bottlenecks in grinding?Although wages are still lower in Turkey, but rising, it appears finding workers and keeping workers that will stay in the unpleasant and dangerous environment of a typical grinding department is becoming harder. Getting the speed required to meet casting production with the high accuracy required is also getting more difficult as most grinding shops are staffed with inexperienced workers.3000 out of a total of 4000 Automatic Grinding Machines installed worldwide are the Koyama Series 400 & 500. Designed by Koyama to solve grinding problems in their own foundries, the guiding principles of the system remain since their initial launch;1. It must be flexible enough that almost 100% of castings can be ground 100% at high speed2. Koyama must be able to be programmed and operated by non skilled foundry workers, not highly skilled programming specialists3. It must be built to a standard that will work 23 hours per day, 6 days a week for 15 years with near 100% uptime and very low running costs.Its not just Atik Metal that have found out the impact Koyama machines make to a foundry. AY Dokum, Estas, Kocak, Ozguven, Cemas, Kaydoksan, Denizgiler, all have bought Koyama and many are now buying their next machines confident in the technology and the return on investment.PS Auto Grinding, represented by ASK TR, Hall 3-B 150. will be demonstrating Series 400S at Ankiros. Please feel free to come and find out what could be in it for your foundry.
Jura Guss GmbH is an order related aluminium foundry with an own model and tool making as well as an own mechanical processing. The capacity reaches from prototype part(s) to small batches, medium and high volume. Among the customers are the well-known European automobile and commercial car manufacturers, the international mechanical engineering and the medicine techniques.This medium sized company, which is run by the owner, employs currently about 275 employees.Furthermore the company is very active in the field of apprenticeship.Since the beginning of 2014, an automatic Koyama K 500 TT XXL machine is in this operation for fettling castings in the practical test, the management had issued following object guidelines:
According to the management, the machine runs fine for some time and met the expected tasks perfectly. "The programming for different components is actually operates as simple and easy as specified by the manufacturer, the staff need for proper operation no special programming skills. Thus, the Koyama range is also suitable for smaller quantities. The automated fettling offers advantages over the known hand fettling techniques that begins at the design of the workplace and goes to the reduced burden on the employee. " "We are on the right track" we are told by a satisfied management, the process safety is absolutely provided. Regarding the issue of the cost savings it was too early for a final costing, but anyway it seems quite clear, that the output goals are achieved and for the future prospective the expansion of automatic fettling at Jura-Guss GmbH is conveivable.Automatic fettling exemplary with a Koyama 500 TT XXL - Distribution: P.S. Auto Grinding Ltd.
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