Manufacturers’ Brass & Aluminum sees Benefits from Industry 4.0 Integration

In today’s competitive manufacturing environment, investing in technology that enhances efficiency and reduces downtime is crucial. Manufacturers’ Brass & Aluminum Foundry (MBAF) recently made a $2 million upgrade to their green sand molding system, incorporating Sinto’s FBO-III automated mold handling system and Industry 4.0 integration. This upgrade has delivered significant improvements in operations, maintenance practices, and production.

The FBO-III system has provided MBAF with access to real-time data on machine performance, fault detection, and cycle times. This integration of smart foundry data has allowed the team to identify and address production issues more effectively. For example, by analyzing production reports, MBAF discovered a drop in mold production during certain times. This insight enabled them to take corrective actions, resulting in a 10% increase in production over several months of data collection.

Another key benefit of their industry 4.0 integration has been the shift from reactive to predictive and preventative maintenance. The smart software generates daily analytics reports, helping the team track faults, their duration, and pinpoint causes. Derek Wilken, MBAF’s Maintenance Project Manager, notes that these reports allow the team to stay ahead of potential issues. The system also has enabled remote troubleshooting: Sinto’s team can log in and assist MBAF in real time, minimizing downtime.

One of the biggest impacts of their Sinto Smart Foundry integration has been in identifying bottlenecks in the pouring process. Before the upgrade, MBAF suspected pouring was causing idle time but lacked concrete data. With the system’s insights, they were able to quantify the downtime between pours and justify increasing pouring capacity with clear return-on-investment (ROI) data. This data-driven approach has made decision-making more informed and strategic.

The cloud-based nature of the system also has offered employees significant flexibility. It allows team members like Wilken, who manages multiple facilities, to monitor operations remotely, ensuring continuous oversight and quick response to issues. Wilken explains, “The fact that we now have software that is all IP-based allows me to monitor wherever I am. I always have an inside scoop on how the machine is running, which helps us stay ahead of any potential issues before they become big problems.”

Overall, MBAF’s investment in new molding equipment with industry 4.0 integration has led to improvements in efficiency, maintenance, and production. By leveraging real-time data and remote monitoring, MBAF has successfully reduced downtime and boosted output, proving that embracing smart manufacturing solutions is key to staying competitive in today’s fast-evolving industry.

Want to know about how SINTO SMART FOUNDRY can benefit you?