SAIPA Malleable Co. Foundry Case Story - DISA 230
Leading car manufacturer SAIPA in Iran buys DISA 230 New Generation moulding machine
With the purchase of a DISA 230 moulding machine, the first in Iran, SAIPA Malleable foundry reinforces its existing DISAMATIC 2013 in a novel plant conversion designed to increase capacity and save finishing costs.
The SAIPA Malleable foundry in Tehran is owned by SAIPA, Iran’s second-largest car manufacturer. SAIPA makes a complete range of models including its own brands as well as licensed production of a number of models from global manufacturers. Recognised internationally for its production quality and holding a number of certificates including QS9000, ISO9000 and ISO14001, SAIPA has a strong competitive position in the booming car market in Iran. The company also exports to other Middle Eastern countries.
Established in 1967, the SAIPA Malleable foundry produces grey iron and ductile iron automotive parts including brake callipers, crankshafts, brake drums and discs, flywheels and cylinder blocks, both for SAIPA’s own models and for other Iranian car manufacturers. In addition to two BMD horizontal moulding lines, the foundry had a DISA moulding line consisting of a DISAMATIC 2013 MK4 moulding machine and a DISACOOL cooling drum.
Higher capacity at lower cost
“Like other foundries all over the world, we are in a highly competitive situation,” says Mr Dehghani, Managing Director of the SAIPA foundry. “The market situation calls for higher capacity in order to keep up with demand, while keeping costs at an absolute minimum.
“We have been very satisfied with our DISAMATIC 2013 MK4 machine as well as the service and support we have received since we purchased it in 1989. Our decision to use the DISA 230-A New Generation moulding machine to increase our moulding capacity was based on our previous experience with DISA and on the higher capacity, lower finishing costs and lower maintenance costs offered by DISA New Generation technology. The older machine continues to run as reliably as ever, so the obvious answer was to retain it together with the new one,” he continues.
Innovative combination
SAIPA’s DISA 230 was the first DISA New Generation moulding machine in Iran. The purchase decision was accompanied by a wish to combine the new machine with the existing DISAMATIC 2013 MK4 in a new foundry line layout permitting the use of the DISACOOL for both machines.
SAIPA discussed with DISA the feasibility of combining the two moulding machines in this way. DISA confirmed that it could be done and suggested a plan entailing the move of the DISAMATIC 2013 MK4 moulding machine to a new location 20 metres away, and installing the DISA 230 in the space the DISAMATIC 2013 MK4 had previously occupied.
New challenge
“Moving a machine of that size even 20 metres was a major challenge,” Mr Dehghani relates. “So we asked DISA to contribute with their project management expertise.”
DISA designed a new layout for the moulding line and drew up detailed plans for relocating the DISAMATIC 2013 MK4. Precautions were taken to ensure safe relocation of the complex and heavy moulding machine. DISA engineers were on-site at critical points along the way to ensure that everything went according to plan.
Introduction to the New Generation
The relocation was successful and, in the meantime, the new DISA 230 machine had arrived. It was installed in the summer of 2006 with both machines feeding the existing DISACOOL cooling drum.
The contract included a six-week applications training course for four key people at the foundry. The first two weeks were held at DISA in Denmark in form of a detailed introduction to the differences between the DISAMATIC, and the DISA New Generation technology.
The final four weeks were held on-site at the foundry, focusing primarily on pattern plate design and DISA New Generation technology, including the advanced control system, in order to ensure optimum production speed and quality from day one.
Excellence in technology and service
Mr Dehghani does not doubt that the service from DISA in form of project planning and management as well as installation, commissioning and applications training made a huge contribution to extending the capacity of the foundry in a cost-effective manner.
The moulding lines are now both running at full capacity and use the same DISACOOL cooling drum. Commenting on the success of the new moulding lines, Mr Dehghani says, “The quality of the near net shape castings from the DISA 230 is noticeably better in that our finishing costs for castings from the New Generation machine are significantly lower.
“Fewer moving parts and the advanced control system have enabled us to optimize our moulding operation to achieve higher speeds and less maintenance downtime, thus increasing our capacity and lowering the cost per kilogramme castings. DISA New Generation technology, together with the service excellence we know we can expect from DISA, is making a significant contribution to the success of our ambitious strategy for the future,” Mr Dehghani concludes.