Are you about to start a project with new forming?  Do you need to reconfigure the plant?  This is a checklist that we have found helpful.  We can help your plant staff think through these things and cover all the bases.

• Flexibility vs Production    We are tempted to purchase too much forming.  The efficiency of a long form is offset by sharp reduction in flexibility.  That costs a lot.  Second, modern batch plant chemicals allow forms to be turned twice a day.  Last, with a self stressing form, you can add more later if you need it.

 
• Finishing  We spend a lot of money on finishing and take the expense for granted.  Vertical cast surfaces never look right, even with SCC.  Ideally all plates and inserts should be held, not jogged in.  Look closely at fins and form joints.  Design forming with the opinion that any finishing and rubbing is rework.

• Crane time    Most plants are bottlenecked by crane time.  Carefully think through pick time, travel paths, laydown.  One of the biggest costs of rework is plant congestion and rehandling costs.

• Vendor participation    The forms maker will typically supply a lot of good production design ideas.  This might be the right time to put up a new mix design.  We can help.

• Staffing    New forming and production should always have a complete staffing plan. This can be prepared by an I.E. but the better and more effective plan is created by the production staff.

• Plant Debottlenecking    This is a process that should be undertaken several times a year.  The result is improved production, reduced wait time, improved productivity.

• Maintenance    Forming gets tired.  The product quality and production efficiency degrades gradually due to cracks, buildup, dents and depressions, ineffective vibration, steam leaks, and the like.  Most plants can benefit from a PM program in this area.

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