CPT International 4/2019

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LOGISTICS environment.” Alexander Heimburger, Sales Manager at the Still branch in Freiburg and in charge of the forklift fleet project confirms that “These optimization potentials came up during the intensive consultation sessions. In addition, the service life of the lead-acid cells was only four years due to maintenance being carried out in the dusty foundry environment and because of the necessary interim charging. The wet-cell batteries of the industrial trucks also lose part of their capacity when the vehicles are used infrequently and irregularly. On the other hand, the constant voltage of the maintenance-free li-ion batteries, i.e. full performance during extremely long service lives, is impressive. Depending on the vehicle’s equipment and demands, use of li-ion technology can be amortized after just one or two years.” The hydraulic system of the RX 70’s tilting device is protected against flying sparks and falling casting residues. Forklift fleet fits as if tailor-made During the last four years, about 50 RX 60 electric forklift trucks with a load capacity of from 2.5 to 5.0 tonnes have been in use for approximately 15,000 hours each without any significant failures. With its heavy castings, the foundry is a classic deployment location for forklift transport vehicles. With 50 different load carriers available, the RX 60 ‘endurance runners’ are responsible for most of the material flow within the works. “Safety has top priority at Fondium. The last time we changed the vehicles we increased the protection for the roof bars, added a protective grid to the cabin roofs, and mounted skirting boards on the driver’s cabin in response to the collisions. In addition, all the front-loaders were equipped with Safety Light 4Plus because pedestrians notice the forklifts quicker and have more time to react thanks to the direction-indicating function of the sequential illumination, made up of four light points,” notes Sascha Heim, the Still salesman responsible for Fondium. Intensive planning and vehicle configuration is necessary in advance of such optimizations. Together with the managers of the various departments, the foundry’s logistics team evaluated the results of such analyses in detail. Manuel Veser: “In many intensive discussions we found again and again that an optimum composition of our fleet would only be possible if the relevant areas in the works departments collaborated. Together with Still, and exploiting Mathis Märgner’s many years of experience in customized forklift fleets, we were able to implement the configurations of the versatile vehicles in many work steps so that we could ultimately order a forklift fleet from Still that was customized for our needs.” When the going gets tough Five robust RX 70-50600 vehicles are used for the heavy transports in the melting shop. The diesel forklifts from Still combine dynamic maneuverability with modern hybrid drive control for particularly low consumption. Over the years a total of 18 special modifications have been made to the compact diesel forklifts to meet the tough demands of the foundry. So, for example, the windscreen is a non-convex heat protection screen mounted in a steel frame. The wings are made of metal, and the headlights and tilt cylinder are equipped with a metal cage to protect the front wheels against flying sparks. An additional heat protection pane has been added above the cabin pane on the right of the driver’s cabin. The hydraulic system of the RX 70 tilting device attachment is also protected against flying sparks and falling casting residues. The tilt mechanism can be safely operated from the driver’s cabin without the need to leave it. Another example is the customized RX 60-25 swivel-seat forklift. Three of these forklift variants are used for the long transport routes. When reversing, an ergonomic sitting position is provided by 45-degree rotation of the driver’s seat and duplicate acceleration and brake pedals. So internal works transports can easily be carried out driving backwards. Reversing is also safer during transport thanks to the enlarged field of view. Well-organized service and maintenance Two Still mechanics are constantly available at the customer workshop in two shifts from 6 a.m. to 6 p.m. During the remaining time and at weekends, a service technician from Still can be at the works within two hours thanks to the agreed on-call service. Additional standby vehicles are also available for particularly important forklifts. “Together with the works logistics team, we have set up an efficient on-site service as part of our shop floor management. Whereby all work-specific information is comprehensibly shown on a board so we can quickly gain an overview of the order processes and tasks in the workshop. Weekly feedback meetings complement this efficient organization,” explains Alexander Heimburger. The immediate result is the extremely high level of industrial truck availability of about 90 percent. Summary Robust, ergonomic, maneuverable and comfortably equipped forklifts are required to handle the extreme stresses with the uneven surfaces in the dusty environment of the foundry. Manuel Veser sums up: “The basis for the good collaboration with Still is the RX 60 ‘endurance runner’. We have had very positive results with these reliable topclass forklifts over many years. In addition, extensive optimization potentials have been opened up with the Still FleetManager and the maintenance-free li-ion warehouse trucks.” www.fondium.eu Redaktionsbüro Gerd Knehr, Gerd Knehr, Reutlingen 38
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Page 3 and 4: EDITORIAL Die-casting in focus! EUR
Page 5 and 6: CONTENTS LOGISTICS Fondium‘s iron
Page 7 and 8: “Today you have to be very agile
Page 9 and 10: Figure 1: Adam Hönig Iron Foundry
Page 11 and 12: Figure 7: Monitor-based control of
Page 13 and 14: Figure 9. Detail view of the furnac
Page 15 and 16: Demonstrator for a measuring techni
Page 17 and 18: MOTIVATED BY CHALLENGES Casting ser
Page 19 and 20: Order your benchmark part now 3D Co
Page 21 and 22: PRESSURE DIE CASTING Photo: Bühler
Page 23 and 24: Situation Today Today’s Market of
Page 25 and 26: 30.00 25.00 20.00 15.00 10.00 5.00
Page 27 and 28: forming of the part and adjusting t
Page 29 and 30: a Nuremberg, Germany 14 -16.1.2020
Page 31 and 32: An automatic extinguishing device i
Page 33 and 34: Romain Zorzi, Project Manager for N
Page 35 and 36: Workpieces before and after blastin
Page 37: Safety has top priority at Fondium.
Page 41 and 42: Plant production in Plüderhausen.
Page 43 and 44: Technician carrying out precision w
Page 45 and 46: PLACE YOUR TRUST IN DEPENDABLE X-RA
Page 47 and 48: The VX1000-PDB also offers space fo
Page 49 and 50: conventional methods. Designers do
Page 51 and 52: INSURAL dosing furnace lining for a
Page 53 and 54: HANDTMANN GROUP New production plan
Page 55 and 56: Die-cast aluminum coil with seven t
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Page 59 and 60: 08.02 Moulding and Coremaking Machi
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Page 63 and 64: ▼ Spheroidal Iron 11540 Behringer
Page 65 and 66: 04.02. Refractory Materials (Shaped
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CPT International 4/2019

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