A computer simulation model of iron distribution from induction furnaces, through treatment steps, with delivery to an automated ductile iron pipe shop, was developed and applied. The problem addressed was variation in metal delivery time from furnace to casting machine, which translated into temperature variation in the machine ladle, hence, in the casting process. The objective was to avoid defects associated with metal that is too hot or too cold, relative to process specifications, and to demonstrate the utility of discrete event simulation in modeling foundry processes. Simulation technology is an ideal tool to enable experimentation with control factors in such complex systems, whereas physical experimentation with the production system is difficult or impossible. Factors contributing the majority of variation to the overall travel time variation were identified, and the use of simulation technology in the foundry was a demonstrated success.
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