DOCUMENT RESUME

ED 352 464 CE 062 554

AUTHOR Mann, Sandra; And OthersTITLE JOBS. A Partnership between Education and

Industry.INSTITUTION Central Alabama Community Coll., Alexander City.;

Robinson Foundry, Inc., Alexander City, AL.SPONS AGENCY Office of Vocational and Adult Education (ED),

Washington, DC. National Workplace LiteracyProgram.

PUB DATE 92CONTRACT V198A10120NOTE 496p.; For a related report, see CE 062 552.PUB TYPE Guides Classroom Use Instructional Materials (For

Learner) (051)

EDRS PRICE MF02/PC20 Plus Postage.DESCRIPTORS Adult Basic Education; Assembly (Manufacturing);

*Basic Skills; Cooperative Programs; *Foundries;*Learning Activities; Lesson Plans; Machine Tools;Metal Industry; *Metal Working; *On the Job Training;Pretests Posttests; Semiskilled Occupations; *SkillDevelopment

IDENTIFIERS *Workplace Literacy

ABSTRACT

This packet contains 15 lessons developed in aworkplace basic skills project for the metal casting industryestablished jointly by Central Alabama Community College and RobinsonFoundry, Inc. The lessons cover the following topics: (1) green sandschedule; (2) the core room; (3) the core roc. (continued); (4)figuring time; (5) the cleaning room; (6) the EPS (EvaporatedPolystyrene System) process; (7) green sand; (8) EPS-1; (9) EPS-2;(10) grinding production sheet; (11) building and grounds; (12)molding production sheet; (13) forms; (14) grinding production sheet;and (15) vocabulary. Lessons contain information sheets, vocabulary(in some cases), technical information particular to the RobinsonFoundry, pretests/posttests with answers, and learning activities foreach of the factory processes covered in the lessons. (KC)

***********************************************************************Reproductions supplied by EDRS are the best that can be made

from the original document.***********************************************************************

JOBS

A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

Central Alabama Community College

Robinson Foundry, Inc.

1992

BEST COPY AVAILABLE

JOBSA National Workplace Literacy Project

P.O. Box 699Alexander City, AL 35010

U.S. DEPARTMENT OF EDUCATION97tOM e of Educational Research and ImprovementE CATIONAL RESOURCES INFORMATION

CENTER (ERIC)

This document has been reproduced asreceived from the person or organuatton04matmg4

C Minor changes have been rna0 at.trnprovereoroductron qualtty ..PorntS 01 view or opinionS slated tn this (woomeet do not necessargy represent officialOERI posthon or policy

JOB

S

A P

AR

TN

ER

SH

IPB

ET

WE

EN

ED

UC

AT

ION

AN

DIN

DU

ST

RY

CENTRAL ALABAMACOMMUNITY COLLEGE& ROBINSON FOUNDRY,

INC.

1992

Researched by

Sandra Mann,

Instructor /Counselor

Beth Maxwell,

Instructor

3

Robert E. Stone,

Project Director

LESSON I

GREEN SANDSCHEDULE

Prepared by

Bonnie Rasmussen:,

Curriculum Consultant

JOBS: 205 329 13481ext. 81

CAM: 205 2346346

4

In th

e fo

llow

ing

less

on o

n th

e G

reen

San

d S

ched

ule

you

will

lear

n ho

w to

rea

d an

dun

ders

tand

the

sche

dule

of j

ob o

rder

s us

ed th

roug

hout

the

Fou

ndry

.

Firs

t, ta

ke th

e qu

iz o

n th

e ne

xt 2

pag

es to

see

wha

t you

alre

ady

know

.

56

2. QUIZ 1

Using the schedule on p. 3,

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hat i

s th

e fla

sk s

ize.

for

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ow d

o yo

u kn

ow th

at a

job

is a

circle the answers you think

the

1st j

ob o

n F

loor

9&

10?

Hot

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r F

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50.

The

Gre

en S

and

Sch

edul

e w

ill k

eep

you

on to

p of

wha

t wor

k is

to b

e do

ne w

hen.

The

follo

win

g qu

estio

ns w

ill h

elp

you

revi

ew w

hat w

e've

cov

ered

so

far.

101

52.

Dire

ctio

ns: C

hoos

e th

e co

rrec

t ans

wer

.W

rite

the

lette

r of

you

r an

swer

inth

e bl

ank.

The

firs

t one

is d

one

for

you.

1. T

his

is a

e.

a. g

reen

san

d sc

hedu

leb.

lost

foam

sch

edul

ec.

SP

C c

hart

2. T

he n

umbe

r '2

0' w

ill b

e pr

inte

dal

ongs

ide

the

patte

rn n

umbe

r on

o. c

astin

gs p

oure

d on

mol

ding

mac

hine

num

ber

20b.

cas

tings

pou

red

on J

anua

ry 2

0c.

cas

tings

pou

red

from

the

softe

st ir

on

3. H

UN

TE

R jo

bs a

re fi

lled

in o

n th

eof

the

Gre

en S

and

Sch

edul

e.

a. b

otto

m li

neb.

top

line

c. m

iddl

e lin

e

1o3

4. A

n ar

row

dra

wn

from

one

squ

are

to in

in fr

ont o

f oth

er s

quar

es m

eans

that

a. th

e jo

b Is

exp

lain

ed o

n th

e O

PO

Sb.

the

job

is a

spe

cial

ord

erc.

the

job

is to

be

done

ear

lier

than

it w

assc

hedu

led.

5. T

he s

peci

al o

rder

not

e fo

r th

e jo

b sq

uare

with

pat

tern

num

ber

7182

73

a.is

exp

lain

ed in

the

note

for

4061

15b.

is e

xpla

ined

in th

e no

te fo

r 71

8273

c.Is

exp

lain

ed in

the

note

for

9015

05

6. T

he c

usto

mer

abb

revi

aito

n 'F

MB

' mea

nsth

e jo

b is

for

a. F

ord

Met

er B

ox C

ompa

nyb.

Sie

men

sc.

Bal

dour

Ele

ctric

Co.

The

cor

rect

ans

wer

s ar

e on

the

next

two

page

s.

104

r.

C" 01 -- R, W LI G. -41 ra la. -, %l c7 .. mrri--izcx

N

<Nru Y

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1

, 0 . .-t

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1":-

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"

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q 4 10

%

C_ N ' .-.

_

(.:1

V \ . .* ".

& '-...

c -...

%

c) _

I / ts,,-

" \ ' ),

.

pz IJ

; t

4 ,...

N

. ,

) N

\4

i N u IN

(I*

'xi ."--', '"'

.1

*-

-,,

--.1-

it ''C

1

1 , )

0 0

I

I

Ni\

V. rie.

,, t .. . ._

,..

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Q.

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4, Ni ' 0 ill

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1

Ut . La

54.

AN

SW

ER

S

1.a.

Thi

s is

the

corr

ect a

nsw

er.

b.T

here

is a

Los

t Foa

m S

ched

ule,

and

a D

ISA

Sch

edul

e, b

ut th

ey a

redi

ffere

nt fr

om th

is o

ne.

c.S

PC

(S

tatis

tical

Pro

cess

Con

trol

) ch

arts

are

use

d at

Rob

inso

n, b

utth

is is

the

Gre

en S

and

Sch

edul

e.

2.b.

Thi

s is

the

corr

ect a

nsw

er.

a.T

he '2

0' m

eans

the

20th

day

of t

he y

ear.

c.T

he '2

0' m

eans

the

20th

day

of t

he y

ear.

3.b.

Thi

s is

the

corr

ect a

nsw

er.

a.R

ead

the

colu

mn

alon

g th

e le

ft ha

nd s

ide

of th

e pa

per

to s

ee w

hich

mac

hine

or

palle

t lin

es th

e jo

bs m

atch

up

with

.c.

Rea

d th

e co

lum

n al

ong

the

left

hand

sid

e of

the

pape

r to

see

whi

chm

achi

ne o

r pa

llet l

ines

the

jobs

mat

ch u

p w

ith.

108

107

55.

4.c.

Thi

s is

the

corr

ect a

nsw

er.

a.A

ll jo

bs a

re e

xpla

ined

on

the

OP

OS

(O

pen

Pur

chas

e O

rder

Sta

tus)

, but

that

has

not

hing

to d

o w

ith th

e ar

row

and

sta

r.b.

Spe

cial

Ord

er jo

bs a

re s

how

n by

'SO

' writ

ten

in th

e br

acke

ts, b

ut th

atha

s no

thin

g to

do

with

the

arro

w a

nd s

tar.

5.b.

Thi

s is

the

corr

ect a

nsw

er.

a.M

atch

the

patte

rn n

umbe

r (7

1827

3) to

the

num

ber

next

to th

e no

te.

c.M

atch

the

patte

rn n

umbe

r (7

1827

3) to

the

num

ber

next

to th

e no

te.

6.a.

Thi

s is

the

corr

ect a

nsw

er.

bT

he a

bbre

viat

ion

for

Sie

men

s is

'Si'.

c.T

he a

bbre

viat

ion

for

Bal

dour

Ele

ctric

is 'B

E'

7.b.

Thi

s is

the

corr

ect a

nsw

er.

a.T

he c

usto

mer

nam

e ap

pear

s in

abb

revi

ated

form

in th

e up

per

right

hand

cor

ner

of e

ach

job

squa

re.

c.T

he n

umbe

r of

mol

ding

s ap

pear

s in

the

cent

er o

val o

n ea

ch jo

bsq

uare

.

re 9

'1

i0

i

56.

Foc

us o

n a

sing

le jo

b sq

uare

Now

let's

look

clo

sely

at a

sin

gle

job

squa

re,

and

revi

ew w

hat e

ach

part

tells

us.

Firs

t,

we

know

that

this

is th

efir

st jo

b fo

r P

alle

t Lin

es 3

&4

on W

edne

sday

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ay 1

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JOBS

A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

LESSON 2THE CORE ROOM

ROBERT E. STONE WRITTEN BY:PROJECT DIRECTOR SANDRA MANN,205 234 6346 INSTRUCTOR/COUNSELOR

205 329 6481 EXT. 81

In the following lesson on the CORE ROOM you will learn about thetwo kinds of cores used at Robinson Foundry.

First, take the quiz on the next page to see what you already know.

CORE ROOM QUIZ 1

DIRECTIONS

Circle the answer you think is correct.

The first one is done for you.

1. How is sand made into a core?

a. It is sifted and packed into a core box.b. It is rammed and packed into a core box.(c.) It is chemically bonded and packed into a core box.

2. Why are cores put in castings?

a. To make the surface finish good.b. To make the outside dimensions accurate.c. To make a hollow space inside the casting.

3. How are Airset cores made?

a. They are made with chemically bonded sand whichhardens when air hits it.

b. They are made with chemically bonded sand whichhardens when the heat of a cast iron core boxactivates the resin.

4. How can you tell if a Shell core is strong?

a. Weigh itb. Look at the color.c. Measure it.

5. How can you tell Airset and Shell cores apart by color?

a. Airset is yellow and brown; Shell is off-white.b. Airset is off-white; Shell is yellow and brown.

6. If you needed cores that were good for detail and dimensionalaccuracy, which would you pick?

a. Airsetb. Shell

159

Most trainees don't know all the answers to the quiz you've justtaken, but after you read the passages and answer the questions onthe following pages, you'll know a lot more about the CORE ROOM.

At the end of the lesson you'll take a quiz and see your scores forboth times.

10

CORE ROOM

The Core Room makes the cores needed for Green Sand castings.Sand is chemically bonded together and packed into a core box toform a shape. The shape, or core, is placed inside the green sandmold. When molten iron is poured into the mold, the sand part doesnot fill up. Instead, there is a hollow shape inside the castingin the exact shape of the core.

There are two processes used in the production of packed sandcores. One process makes an Airset core. The other process makesa Shell core.

**ANSWER THE FOLLOWING QUESTIONS**

DIRECTIONS

Chose the correct answer. Circle the letter of your answer.

1. What is the passage mostly about?

a. How cores are made.b. Core set-up for Green Sand Castings.c. Airset cores.

2. What are the two types of cores made in the core room?

a. Bonded and Packed.b. Airset and Shell.c. Molten and Hollow.

3. Why are cores needed in casting?

a. To make a hollow space inside a casting.b. To make gating for Green Sand molds.c. To chemically bond sand.

CHECK YOUR ANSWERS ON THE NEXT PAGE.

161

ANSWERS

1. a. This answer is correct.

b. This is not mentioned in the passage.c. Airset is mentioned; however, the passage

talks about more information than justairset cores.

2. b. This answer is correct.

a. Bonded and packed are words describing howcores are made. They do not name thetwo types of cores.

c. Molten is a word which is used to describeiron. It is not about cores.

Hollow is used to tell the shape of the insideof a shell core. It is not the type of core.

3. a. This answer is correct.

b. This is not mentioned in the passage.c. To chemically bond sand is how cores are made,

not why they are needed in castings.

1C2

Airset

Airset cores harden when air hits them. They are make fromchemicals and sand grains mixed together and heated in the mixingmachines.

Airset sand is mixed in two different-sized mixing machines.The 150 mixer prepares sand for the smaller cores. The chemicalbalance and temperature help the sand mixture harden quickly.

The 300 mixer prepares sand for larger cores. The sand fromthe 300 machine sets slower because the cores ara so much bigger.

Airset cores are solid. They are generally made in bodieswhich are glued together at the glue-up table. The glue seams aresealed to keep the hot iron from melting the glue seam.

Airset cores are off-white in color. They are generally notdesigned for use in castings that need a good surface finish or ahigh degree of dimensional accuracy. They tend to swell as theyset up. The swelling can make the dimensions of the castings bewrong and can cause defects.

Shell Core

Shell cores are made of resin coated sand. Heat bonds thegrains of sand. The sand comes to Robinson with the resin areadyadded.

Shell cores are made in machines which have cast iron coreboxes. An operator fills the core box with sand. The heat of thecore box activates the resin and bonds the sand to make a core.

Shell cores can be solid or hollow. If the core is not heatedlong enough, there will be a hole in the bottom. Any un-bondedsand will drain out and leave a hollow core.

The color of the Shell core is an indicator of its quality.The darker the Shell core is "cooked" without burning it black, thestronger the core will be. The strongest core is a dark brown.

Shell cores are good for castings requiring detail anddimensional accuracy.

1C3

**ANSWER THE FOLLOWING QUESTIONS**

DIRECTIONS

Choose the correct answer. Circle the letter of your answer.

1. After reading the passage about Airset and Shell cores, youshould be able to the difference between the cores by lookingat the...

a. sizeb. colorc. shape

2. If you needed cores that were good for detail and dimensionalaccuracy, you would pick...

a.b.

Airset coresShell cores

3. If you needed a very strong Shell core, which would you pick?

a. A light yellow oneb. An off-white onec. A dark brown one

4. Casting Number 9804 needs a hollow core. Which would you sendto the Green Sand Pallet line?

a. Airsetb. Shell

5. Core Number 405926 is a very large Airset core. Which sandmixer would you use to make this core?

a. 150b. 300

6. If you put resin-coated sand in a heated cast iron core box,what would you get?

a. An Airset coreb. A Shell core

7. After reading the lesson about the Core Room you should knowthat cores are...

a. only mixed in the 300 machine.b. made from chemically bonded sand.c. always solid.

CHECK YOUR ANSWERS ON THE NEXT PAGE.

164

Answers

1. b. This answer is correct.

a. The passage does not mention the size of the cores.b. The passage does not mention the shape of the cores.

2. b. This answer is correct.

a. Read the last paragraph about Airset Cores. You willlearn why airset cores are good for detail anddimensional accuracy.

3. c. This answer is correct.

a. Read the passage about Shell cores. It explains thatthe strongest Shell cores are dark brown.

b. Airset cores are off-white.

4. b. This answer is correct.

a. Airset cores are solid.

5. b. This answer is correct.

a. The 150 machine makes small cores.

6. b. This answer is correct.

a. Airset sand does not have resin. Airset sand is heatedand mixed in a mixing coaching, not a core box.

7. b. This answer is correct.

a. The 300 machine is only for large Airset, not allcores.

c. Airset cores are solid, but Shell cores are hollow.

105

FOCUS ON VOCABULARY

As you were reading the lesson, did you find words you didn't know?You could have gone to the dictionary to find the meaning of thestrange word OR you could have guessed the word by looking atthe other words around it.

This is called "looking at the CONTEXT of a word".

CONTEXT is the rest of the sentence or paragraph.

Let's look at a sentence from the lesson and see if you can figureout the meaning of an underlined word by looking at the rest of thesentence.

"When molten iron is poured into the mold, the sandpart does not fill up."

In the sentence, molten is in front of iron.what kind of iron is being used.

The next part of the sentence tells you thatthe mold.

You should ask yourself, "What form doeshave to pour it?"

Your answer should be, "A liquid!"

You have figured out that molten means liquid iron. You did thatby looking at the rest of the sentence and asking yourselfquestions.

It is telling you

iron is poured into

iron have to be if you

Now, try your new skill with the questions on the next page!

16

DIRECTIONS

Choose the correct answer. Circle the letter of your answer.

1. What is the meaning of generally in the sentence below?

Airset cores are generally not used in castings that need ahigh degree of dimensional accuracy.

a. most of the timeb. having high rankc. belonging to all persons

2. What is the meaning of bonded in the sentence below?

Sand is chemically bonded together and packed into a corebox to form a shape.

a. a written agreementb. stuck togetherc. a note of debt that is due

3. What is the meaning of activates in the sentence below?

The heat of the core box activates the resin and bonds thesand to make a core.

a. to place on active military dutyb. to cause something to start working

4. What is the meaning of indicator in the sentence below?

The color of a Shell core is an indicator of its quality.

a. a pointer on an instrumentb. something that points out or makes knownc. a by-product

5. What is the meaning of process in the sentence below?

One process makes an Airset core.

a. court summonsb. lines of things moving alongc. a way of doing something

CHECK YOUR ANSWERS ON THE NEXT PAGE.

/

I CS

ANSWERS

1. a. This answer is correct.

b. Rank has nothing to do with castings or dimensionalaccuracy.

c. The sentence is not about people or ownership.

2. b. This is the correct answer.

a. A bond can be a written agreement; however, in thesentence bonded is before the word together. Theword is not used to talk about an agreement.

b. A bond can be a debt that is due; however, in thesentence bonded is not used to talk about debt.It is used to show how sand is put together to makea core.

3. b. This answer is correct.

A. The word activates is used to show what the heat of thecore box does. Military duty is not discussed in thesentence.

4. b. This is the correct answer.

a. An indicator can be a pointer on an instrument;however, the sentence does not discuss instruments.

b. The color of a Shell core shows how good it is. Thecolor is not a by-product.

5. c. This answer is correct.

a. A court summons can be processed; however, it hasnothing to do with making Airset cores.

b. A line of things moving along has nothing to do withmaking Airset cores.

You have completed the lesson.

Go on to the next page to retake the quiz you started this bookletwith, or go back and review the lesson before taking the quiz.

170

CORE ROOM QUIZ 2

DIRECTIONS

Circle the answer you think is correct.

The first one is done for you.

1. How is sand made into a core?

a. It is sifted and packed into a core box.b. It is rammed and packed into a core box.(c.) It is chemically bonded and packed into a core box.

2. Why are cores put in castings?

a. To make the surface finish good.b. To make the outside dimensions accurate.c. To make a hollow space inside the casting.

3. How are Airset cores made?

a. They are made with chemically bonded sand whichhardens when air hits it.

b. They are made with chemically bonded sand whichhardens when the heat of a cast iron core boxactivates the resin.

4. How can you tell if a Shell core is strong?

a. Weigh itb. Look at the color.c. Measure it.

5. How can you tell Airset and Shell cores apart by color?

a. Airset is yellow and brown; Shell is off-white.b. Airset is off-white; Shell is yellow and brown.

6. If you needed cores that were good for detail and dimensionalaccuracy, which would you pick?

a. Airsetb. Shell

171

;

Check the next page for the correct answers to the quiz.

1 '7 e,1 I 4

ANSWERS

1. This one is done for you.

2. c. This answer is correct.

a. Airset cores are not used in castings that need a goodsurface finish; therefore, this cannot be the correctanswer.

b. The reading passage does not mention outside dimensions.

3. a. This answer is correct.

b. This is how Shel4 cores are made.

4.. b. This is the correct answer.

a. The passage does not mention weighing castings.b. The passage does not mention measuring castings.

5. b. This answer is corect.

a. Read the parts of the passage which tells about thecolor of each shell.

6. b. This is the correct answer.

a. Read the passage about Airset cores. They swell asthey set up. This can make a casting have a defect.

JOBS

A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

LESSON 3

THE CORE ROOM

ROBERT E. STONE, WRITTEN BY:PROJECT DIRECTOR BETH MAXWELL,205 234 6346 INSTRUCTOR

205 329 8481 EXT. 81

WORD LIST

I. CORE

2. MOLD

3. FLASK

4. SAND

5. CASTING

6. GREEN SAND

7. EPS

8. FINS

CORE ROOM

1 7F)

CORE ROOM

Willie works in the core room. He helps make cores to go

inside a mold. The molds are placed in a flask. The sand in the

mold makes the form of the casting. The casting comes from

Green Sand or EPS process. Fins are found on some castings.

Circle the following words in the passage:

1. core

2. mold

3. flask

4. sand

5. casting

6. Green Sand

7. EPS

8. fins

ft)

CORE ROOM

Willie works in the room. He helps make to go

inside a . The are placed in a . The

in the makes the form of the . The

comes from or process. are found

on some

Word List:

1. core

2. mold

3. flask

4. sand

5. casting

6. Green Sand

7. EPS

8. fins

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Words -- circle the matching words.

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1. FLASK

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2. SLAG

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1E1

FIND THE DEPARTMENTS ON THE MAP

1. Personnel and Lab

2. Supply

3. Cleaning Room

4. Shipping

5. Pattern Shop

6. Iron Melting

7. EPS

8. Green Sand

9. Disa

10. Core Room

11. Storage

12. Storage

13. Maintenance

14. Security

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JOBS

A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

LESSON 4FIGURING TIME

ROBERT E. STONE WRITTEN BY:PROJECT DIRECTOR SANDRA MANN,205 234 6346 INSTRUCTOR/COUNSELOR

205 329 8481 EXT. 81

In the following lesson on Figuring Time you will learn how to workwith time problems.

First, take the quiz on the next page to see what you already know.

L.

TIME PROBLEMS-QUIZ 1

1. Jessie Tolison's shell core machine broke down for 44 minutesand was out of sand for 10 minutes. The power was off for 17minutes. What is his total DOWN TIME for that day?

a. 1 hour and 5 minutesb. 1 hour and 11 minutesc. 75 minutesd. none of the above

2. Derrick Spivey worked 2 hours and 37 minutes overtime onMonday and 1 hour 53 minutes overtime on Tuesday. Howmuch is his OVER TIME for both days?

a. 4 hours and 30 minutesb. 3 hours and 87 minutesc. 3 hours and 60 minutesd. None of the above

3. At 6:51 the Melt Deck ran out of iron. James McCoy needed topour castings but he has to wait for iron. It's 8:10 before hegot any iron. How long did he wait?

a. 1 hour and 45 minutesb. 2 hoursc. 1 hour and 19 minutesd. none of the above

4. Celso Cruz works from 10:35 pm to 6:15 am every day. How manyhours is he at work?

a. 7 hours and 40 minutesb. 6 hours and 35 minutesc. 8 hours and 10 minutesd. none of the above

5. Howard Marcantel goes to work at 4:40 am and gets off at1:15 pm. He takes 45 minutes for lunch and takes two 10minute GatorAde breaks. How many hours a day does heactually work?

a. 7 hours and 50 minutesb. 8 hoursc. 7 hours and 30 minutesd. none of the above

6. Jay Edmondson goes to work at 4:10 am and works 9 hours and15 minutes. What is his quitting time?

a. 1:45 pmb. 2:30 pmc. 1:25 pmd. none of the above

1L7

TIME PROBLEMS AT ROBINSON FOUNDRY

An important job skill is to be able to fill out theoccupational forms used in your department. Many occupationalforms are used to record the amount of work which has been done ina certain amount of time.

These forms are called PRODUCTION FORMS. In order tocorrectly fill out productions forms, you must be able to writeclock time.

If your work is stopped for some reason, you have to write theamount of DOWN TIME. This means you must be able to add andsubtract time.

This booklet will show you quick and easy ways to figure timeproblems in your work.

ADDING TINE

Here is an example of writing DOWN TIME on a Robinsonproduction form:

Suppose your molding machine broke down for 15 minutes. Thenthe power went off for 12 minutes. Next, you took a break for10 minutes.

What will you write for your total DOWN TIME?

Add the minutes together like this

15 minutes12 minutes10 minutes <

37 minutes

NOW TRY THIS ONE!

It takes you 40 minutes to eat lunch. You take two 10 minutebreaks. You are out of iron for 35 minutes.

What will you write for TOTAL DOWN TIME?

Add the minutes like this:

40 minutes10 11

10+ 35

95 minutes

95 minutes is the right answer---however---you must writeDOWNTIME in hours and minutes.

Look below to see how to do this:

Divide the minutes by 60 (minutes in an hour).

1 > number of hours

60 I 95- 60

35 > number of minutes

You would write 1 hour and 35 minutes for DOWN TIME.

Change these minutes into hours and minutes:

a.b.c.d.e.

857692

14765

CHECK YOUR ANSWERS ON THE NEXT PAGE

n.4- al ti

ANSWERS

a. 1 hour and 25 minutesb. 1 hour and 16 minutesc. 1 hour and 32 minutesd. 2 hour and 27 minutese. 1 hour and 5 minutes

If you do not understand why these answers are correct,ask your teacher for help.

MORE ADDING PROBLEMS

Suppose you worked overtime 3 afternoons this week. You worked1 hour and 25 minutes on Monday. You worked 2 hours and 10minutes on Tuesday. You worked 1 hour and 15 minutes onWednesday.

How can you find out the total amount of overtime you haveworked this week?

DO IT LIKE THIS

1:252:10

+ 1:15

4:50

**You worked 4 hours and 50 minutes**

1b2

LET'S TRY ANOTHER PROBLEM

Suppose you worked 1 hour and 45 minutes overtime on Monday.Then you worked 1 hour and 45 minutes overtime on Tuesday.

How much time did you have in overtime pay?

* * * If you add your time like this

1:45+ 1:45 <

2:90

* * *

Your answer is correct,but it just doesn't look right!

Your minutes have added up to more then an hour.WHAT DO YOU DO NOW?

Divide the minutes by 60 (minutes in an hour)

1 > 1 hour and 30 minutes

60 190-60

30 <

Now add Thour and 30 minutes to 2:00

2:00+ 1:30

3:30

*** You have 3 hours and 30 minutes in overtime pay! ***

SUBTRACTING TIME

Let's do problems with subtracting time.

The Muller breaks down at 10:47 am. You can't run your moldingmachine without sand. The Muller isn't fixed until 11:15 am.

How much DOWN TIME should you write on the Molding productiosheet?

*** You could write the problem like this

11:15- 10:47

But that won't work!You can't subtract 47 from 15.

* * *

Look at the problem worked like this:

Borrow an hour11:15

- 1:00

10:15

Change the hour to 60 minutes and add back to 10:15

10:15+ :60

10:75

NON you can subtract 10:47 and find the DOWN TIME.

10:75- 10:47

:28

*** You will write 28 minutes as your DOWN TIME. ***

154

Let's do a few more of these problems

1. You work in the cleaning room at a grinding booth. TodayRoy Watts sent you a pallet of castings with the number63196008. You start grinding at 2:43. By 5:06 you only had 5castings ground.

How long did it take you to do that work?

a. 3 hours and 5 minutesb. 2 hours and 23 minutesc. 1 hour and 47 minutesd. none of the above

(Did you remember to "borrow" 60 minutes?)

2. You work in EPS Assembly. Rick Johnson brings you a box offoam patterns to assemble. You begin at 7:00 am. Normally,you get through with this box by 7:50 am. Today you work until8:23 am.

How much extra time did you spend working on this box?

a. 45 minutesb. 1 hour and 23 minutesc. 33 minutesd. none of the above

CHECK YOUR ANSWERES ON THE NEXT PAGE

ANSWERS

1. The correct answer is b. Work the problem like this:

Step 1. 5:06 You can't subtract this problem.-2:43

Step 2. You have to borrow an hour from 5:06.

5:06-1:004:06

Step 3. Change the hour to 60 minutes and add it backto 4:06

4:06+ :604:66

Step 4. NOW you can subtract 2:43 from 4:66 and findthe time.

4:66- 2:43

2:23

Step 5. Write the answer as 2 hours and 23 minutes.

2. The correct answer is c. Work the problem like this:

Step 1. 'et up the problem.

8:23- 7:50

Step 2. Change 8:23 by borrowing an hour and adding itback as 60 minutes.

8:23- 1:00

7:23

7:23Then do this: + :60

7:83

Step 3. NOW you can subtract and find the extra time.

7:83 new finishing time- 7:50 normal finishing time

33 minutes extra time spent of the box.

Let's look at another problem involving SUBTRACTING TIME.

Suppose you work from 6:15 am to 2:00 pm.

How long are you at work?

* * * You could write the problem like this.

2:00 pm- 6:15 am----

* * *

But that won't work!You can't subtract a large number from a smaller number.

TRY THIS

Change your quitting time to a number that is large enough toallow you to subtract your starting time. You can do that byadding your quitting time to 12:00 noon...just like this.

12:00 noon+ 2:00 pm (quitting time) <

14:00 pm (NEW quitting time)

*** NOW write the problem like this ***

14:00 pm = (don't forget to borrow) = 13:60 pm- 6:15 am - 6:15 am

Olw7:45

You are at work 7 hours and 45 minutes!

TRY IT AGAIN!

1. You go to work in EPS at 8:05 am. You get off early at1:15 pm.

How many hours did you work today?

a. 5 hours and 10 minutesb. 5 hours and 20 minutes=. 4 hours and 55 minutesD. none of the above

2. You start work in the Core Room at 4:43 am and quit work at1:25.

How long did you work today?

a. 9 hours and 10 minutesb. 8 hours and 42 minutesc. 8 hours and 18 minutesd. none of the above

3. You are working overtime at the Cleaning Room. You start workat 4:10 am and you regulary get off at 12:15 pm. However,today you work until 2:23 pm. Answer the following questionsabout your time at work:

(a) How many hours did you work today?(b) How many hours do you work without overtime?(c) How much overtime did you work today?

CHECK YOUR ANSWERS ON THE NEXT PAGE

128

ANSWERS

1. The correct answer is a.

2. The correct answer is b.

3. The correct answer is:

a. 10 hours and 13 minutesb. 8 hours and 5 minutesc. 2 hours and 8 minutes

If you do not understand why these answers arecorrect, ask your teacher for help.

0 C._a_ ti

OTHER TIME PROBLEMS

Let's look at another type of time problem.Sam Huntley came to work at 7:10 am. He hid behind the CoreRoom and took 35 minutes to eat 2 steak biscuits. He watchedRobert Angle rake leaves for 30 minutes. He hid in Annette'soffice for 15 minutes and drank a cup of coffee. He went homeat 2:45 pm.

How many hours did Sam actually work today?

DO IT LIKE THIS

Add the "goof-off" time----> 35 minutes30 "

+ 15 "

80 I I

Chan 80 minutes to hours and minutes----> 1 hour and 20 minutes

Find how how long Sam was at Robinson--->

(1) 2:45 (quitting time)+ 12:00 noon

14:45 (new quitting time)

(2) 14:45 (new quitting time)- 7:10 (starting time)

7:35 Hours at Robinson

Subtract the DOWNTIME (the "goof-off" time) from the hours he wasat Robinson

7:35 (hours he was at Robinson)- 1:20 ("goofing-off" time)

6:15

Sam actually worked 6 hours and 15 minutes!

,

Let's look at another TIME PROBLEM.

1. If you go to work at 6:10 am and work 8 hours, what will beyour quitting time?

DO IT LIKE THIS:

step 1. 6:10 am (starting time)+ 8:00 (hours at work)

14:10 pm (quitting time)

stlp 2. 14:10 pm-12:00 noon

2:10 pm (quitting time in clock time)

Your quitting time is 2:10!

TRY THIS ONE!

You come into EPS at 5:30 and start work. Joe Clark comes byand tells you that you have to work 10 hours and 45 minutestoday.

This if fine with you because you need the extra overtime;however, you carry riders in your car. They only have to work8 hours today.

1. What time will you L.0 11 your riders that you will be leavingwork?

a. 3:76 pmb. 2:45 pmc. 4:15 pm

2. If your riders went to work at 5:30 and worked 8 hours, howlong will they have to wait for you after they get off work?

a. 2 hours and 45 minutesb. 3 hoursc. 4 hours and 15 minutes

CHECK YOUR ANSWERS ON THE NEXT PAGE

Ao°04r-'

ANSWERS

1. The correct answer is b.

2. The correct answer is a.

If you do not understand why these answers arecorrect, ask your teacher for help.

You have completed the lesson.

Go to the next page to take a practice quiz to see how well youhave learned to figure time.

Check your answers to see if you need to review the lesson beforeyou take the last quiz.

2C 4

TIME PROBLEMS Practice Quiz

1. James Baggett's molding machine broke down for 27 minutes. TheMuller stopped for 35 minutes and he couldn't get sand. Apattern change took 25 minutes.

What is his total DOWNTIME for the day?

a. 1 hour and 10 minutesb. 1 hour and 27 minutesc. 1 hourd. none of the above

2. Charles Mather worked 1 hour and 53 minutes overtime onWednesday and 2 hours and 43 minutes overtime on Thursday.

How much is his overtime for both days?

a. 4 hours and 36 minutesb. 4 hours and 15 minutesc. 3 hours and 67 minutesd. none of the above

3. Harry Brown runs the Hunter molding machine. He had towait from 6:54 am to 8:17 for sand.

How long did he wait?

a. 2 hours and 3 minutesb. 1 hour and 23 minutesc. 2 hoursd. none of the above

4. Rose Ware works from 4:40 am to 1:13 pm.

How many hours a day is she at work?

a. 9 hours and 13 minutesb. 7 hours and 45 minutesc. 8 hours and 33 minutesd. none of the above

205

5. Wayne Browning goes to work at 5:48 am and gets off at 2:10 pm.He takes 35 minutes for lunch anu takes two 15 minute breaks.

How many hours a day does he actually work?

a. 6 hours and 13 minutesb. 7 hours and 17 minutesc. 8 hours and 22 minutesd. none of the above

6. Tommy Green goes to work at 4:17 am and works 10 hours and 35minutes.

What is his quitting time?

a. 3:10 pmb. 2:52 pmc. 2:18 pmd. none of the above

**CHECK YOUR ANSWERS ON THE NEXT PAGE**

2C6

ANSWERS

1. The correct answer is b.

2. The correct answer is T.

3. The correct answer is b.

4. The correct answer is c.

5. The correct answer is b.

6. The correct answer is b.

If you missed many of these questions, ask your teacher tohelp you find the places in the lesson you need to review.

If you are ready, go the the next page and retake the quizyou took when you started this booklet.

TIME PROBLEMS-QUIZ 2

1. Jessie Tolison's shell core machine broke down for 44 minutesand was out of sand for 10 minutes. The power was off for 17minutes. What is his total DOWN TIME for that day?

a. 1 hour and 5 minutesb. 1 hour and 11 minutesc. 75 minutesd. none of the above

2. Derrick Spivey worked 2 hours and 37 minutes overtime onMonday and 1 hour 53 minutes overtime on Tuesday. Howmuch is his OVER TIME for both days?

a. 4 hours and 30 minutesb. 3 hours and 87 minutesc. 3 hours and 60 minutesd. None of the above

3. At 6:51 the Melt Deck ran out of iron. James McCoy needed topour castings but he has to wait for iron. It's 8:10 before hecot any iron. How long did he wait?

a. 1 hour and 45 minutesb. 2 hoursc. 1 hour c..nd 19 minutesd. none of the above

4. Celso Cruz works from 10:35 pm to 6:15 am every day.hours is he at work?

a. 7 hours and 40 minutesb. 6 hours and 35 minutesc. 8 hours and 10 minutesd. none of the above

How many

5. Howard Marcantel goes to work at 4:40 am and gets off at1:15 pm. He takes 45 minutes for lunch and takesminute GatorAde breaks. How many hours a day does

twohe

10

actually work?

a. 7 hours and 50 minutesb. 8 hoursc. 7 hours and 30 minutesd. none of the above

6. Jay Edmondson goes to work at 4:10 am and works 9 hours and15 minutes. What is his quitting time?

a. 1:45 pmb. 2:30 pmc. 1:25 pmd. none of the above

2CS

1. The correct answer is b.

2. The correct answer is a.

3. The correct answer is c.

4. The correct answer is a.

5. The correct answer is c.

6. The correct ahswer is c.

ANSWERS

r) r Q4 I.- .7

JOBS

A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

LESSON 5

THE CLEANING ROOM

ROBERT E. STONE, WRITTEN BY:PROJECT DIRECTOR BETH MAXWELL,205 234 6346 INSTRUCTOR

205 329 8461 EXT. 812 :

WORD LIST:

i. Cleaning Room

2. grind

3. casting

4. core

5. sand

6. mold

7. fins

8. Green Sand

9. EPS

10. defects

11. scrap

12. safety

13. Jessie

CLEANING ROOM

211

CLEANING ROOM READING

Jessie works in the cleaning room in the foundry His job

is to grind castings to finish casting for shipping. The core and

sand have already been removed from mold of casting. Jessie must

be very careful with fins on castings. They can easily break off.

The cleaning room puts finishing touches on castings from Green

Sand as well as EPS. In the cleaning room Jessie must notice

castings to make sure there is no defects. Defects on castingsmeans the castings must be considered scrap and must be remelted.

safety is very important in the cleaning room. There is blowing

particles from large blowers in the cleaning room. There is a

great deal of noise in the cleaning room. A worker in the cleaning

room must wear safety glasses, earplugs, and steel toed shoes.

Circle the words in the reading above:

1. cleaning room2. grind3. casting4. core5. sand6. mold7. fins8. Green Sand9. EPS10. defects11. scrap12. safety13. Jessie

4,14,;Th

Cleaning Room Reading

Fill in missing words:

Jessie works in the room in the

foundry. His job is to

to finish for shipping. The

and have already been removed from of

. Jessie must be careful with

on . They can easily break off. The

room puts finishing touches on

from as well as

. In the room Jessie must notice

to make sure there is no

on means they must be

considered and must be remelted.

is very important in the room. There is

blowing particles from large blowers in the

room. There is a great deal of noise in the

room. A worker in the cleaning room must

wear glasses, earplugs, and steel toed shoes.

Fill in missing:

an r in s d

cl ni g o m s ncenn ro nd

ani om salaigom an

nd

gri

m 1

ld

ato

m d

ol

ting

c t g f n

csigt g in

cas

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Gr n S n

G nSdGenSn

en Sa

Gre d

21 4

1. st2. b d

3. j k

4. x z

5. m n

6. f g

7. o p

8. h j

9. p r

10. v w

11. a b

12. j k

13. d f

14. x y

15. g h

16. s u

17. n p

18. 0 f

19. h i

20. t u

fn:Beth\alpha

PREACTIVITY FOR A to 2

0140.11.4.)

PREACTIVITY FOR ALPHABETICAL ORDER

1. FLASK 1.

2. ACCIDENT 2.

3. CORE 3.

4. SAND 4.

5. PATTERN 5.

1. MOLD 1.

2. SLAG 2.

3. FIN 3.

4. EPS 4.

5. CASTING 5.

1. DEFECT 1.

2. SCRAP 2.

3. BP 3.

4. SAFETY 4.

5. HAMMER 5.

FN:BETH\ALPHA2

2

FIND THE DEPARTMENTS ON THE MAP

1. Personnel and Lab

2. Supply

3. Cleaning Room

4. Shipping

5. Pattern Shop

6. Iron Melting

7. EPS

8. Green Sand

9. Disa

10. Core Room

11. Storage

12. Storage

13. Maintenance

14. Security

and

Col

or2r

ec,i1

-1

Pa4-

4n

Sloe eD

.RV

I)1,

S

S

Sam

ci

Cor

e (Roo

m

Ro6

inSo

nFo

tkcl

-ni

2

JOBS

A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

LESSON 6

THE EPS PROCESS

ROBERT E. STONE WRITTEN BY:PROJECT DIRECTOR SANDRA MANN,205 234 6346 INSTRUCTOR/COUNSELOR

205 329 0481 EXT. 81

In the following lesson on The EPS Process you will learnhow EPS castings are made.

First, take the quiz on the next 2 pages to see what youalready know.

221

EPS - -Quiz 1

DIRECTIONS

Circle the answer you think is correct. The first one is done foryou.

1. What does EPS mean?

a. Exothermic Polystyrene Styrofoamb. Expandable Process Styrofoam{c.} Evaporated Polystyrene System

2. How old is the "lost foam" process?

a. over 3000 years oldb. over 300 years oldc. over 30 years old

3. What are EPS patterns made of?

a. excess styrofoamb. expandable polystyrene beadsc. iron, aluminum, plastic, or wood.

4. Which of the following is an important part of the foamassembler's job?

a. Making a strong glue seam between the pattern andthe gating.

b. Making sure the pattern is completly covered bythe coating.

c. Setting the sprue correctly.

5. Why are EPS patterns dipped in a coating?

a. To keep the styrofoam from melting.b. To eliminate mold wall movement.c. To keep the iron from touching the sand when the

iron is poured.

222

6. Why is EPS called "Lost Foam"?

a. Because EPS castings have fewer defects and have"lost" the need for grinding.

b. Because the pattern evaporates when the molteniron hits it.

c. Because EPS castings have "lost" the extra metalsuch as the parting line.

7. Why are EPS castings better than Green Sand castings?

a. Tolerance bands are higher.b. Better dimensional accuracyc. Sand binders eliminate gas defects.

Most trainees do not know all the answers to the quiz you'vejust taken, but after you read the passage and answer thequestions on the following pages, you'll know a lot more aboutthe EPS process.

At the end of the lesson you'll take a quiz and see yourscores for both times.

flAC44

r-,. i,

EPS...The "Lost Foam" Process

EPS stands for Evaporated Polystern System. This new way ofmaking castings was invented by H. F. Shroyer in 1958. Castingsare made by pouring molten metal into styrofoam patterns.

This is a new way of making castings. The Green Sand way ofmaking castings is thousands of years old.

Robinson began making EPS castings in 1984. The process isstill new, and Robinson is still making improvements,

***ANSWER THESE QUESTIONS***

DIRECTIONS

Circle the letter of your answer choice.

1. What is the passage mainly about?

a. EPS is a new way of making castings.b. H.F. Shroyer invented EPS in 1958c. EPS castings are made out of styrofoam.

2. When did Robinson start making EPS Castings?

a. 1958b. 1984c. 1989

CHECK YOUR ANSWERS ON THE NEXT PAGE

ANSWERS

1. a. This is the correct answer.

b. While this is true, other information is discussed in thepassage.c. While this is true, other information is discussed in thepassage.

2. b. This is the correct answer.

a. G.F. Shroyer invented EPS in 1958. Robinson did notbegin making EPS castings until 1984.

c. This is an incorrect date.

226

OUTLINE OF THE EPS PROCESS

EPS patterns are made from expandable polystyrene beads. Thebeads are heated and injected into a mold. The heat makes thebeads puff up and stick together. This process makes foam patternpieces in the shape of castings.

Robinson does not make EPS patterns. They buy them fromdifferent companies. When the pieces come to EPS. Receiving andInspection, the Robinson worker weighs them. The patterns are sentto Foam Assembly.

The workers in Foam Assembly must first check the patternpieces for defects. Next, the workers must glue together patternpieces and attach the gating. The glue is a 'hot melt adhesive".The glue seam between the pattern piece and the gating must be verystrong. To make a good seam, the glue must be between 260-290degrees in temperature.

Next the patterns go to the Dipping Area. The patterns aredipped in a refractroy coating. The coating will keep the ironfrom touching the sand when the casting is poured. The coatedpatterns are put in a dryer. Each piece is weighed after dippingand after drying.

The patterns go to the Cluster Table. The patterns are gluedtogether into groups called clusters.

The patterns clusters are moved to Molding. The clusters areput into a special flask and covered with unbonded sand.

Next, the flasks move around to the Pouring Station. Molteniron is poured into the flasks. The hot iron hits the foam patternand evaporates, or melts, it. This is why the EPS process iscalled "lost foam. The foam is "lost" when the iron hits it. Themetal then fills the hole left by the pattern.

After pouring, the flasks move to Shakeout. The castings areremoved from the sand and sent to the Cleaning Room. The sand incooled for reuse in the process.

***ANSWER THE QUESTIONS ON THE FOLLOWING PAGE***

1

DIRECTIONS

Circle the answer you think is correct. The first on is done foryou.

1. How are EPS patterns made?

{a}

b.c.

Expandable polystyrene beadsa mold.

Wood masters are cut on theThe bead collapse is filled

are heated and injected into

lathe in the pattern shop.into the mold.

2. According to the passage, if you worked in Receiving, whatwould be your job responsibility?

a. gluing the gatingb. assembling the patternsc. weighing the patterns

3. After reading this passage, you should know that an importantpart of an Assembler's job is to

a. weigh the pattern piecesb. keep the glue temperature within specificationc. sand the gating edges

4. According to the passage, why is the coating important?

a. It keeps the gating from melting.b. It keeps the from touching the sand.c. It keeps the glue seam from melting.

5. According the passage, if you worked in Dipping, which of thefollowing skills would you need?

a. To be able to fill out a time sheet.b. To be able to read a weighing scale.c. To be able to read a Zahn scale.

6. After reading the passage, you should know that a cluster isthe

a. gating glued on correctlyb. patterns glued togetherc. refractory coating

2 2

7. Which sand is used in EPS flasks?

a. bondedb. unbonded

8. Why is EPS called "Lost Foam"?

a. The hot iron evaporates,b. The castings have "lost"

as the parting line.c. The castings have "lost"

or melts, the foam.the extra metal such

the need for grinding.

9. According to the passage, which of the following tellshow iron makes an EPS casting?

a. It melts the refractory coating.b. It fills the hole left by the evaporated pattern.c. It moves thru the gating and then through the sprue.

CHECK YOUR ANSWERS ON THE NEXT PAGE

2Z9

ANSWERS

1.

2.

a.

c.

This answer is correct.

b. This is the way Green Sand patterns are made. Thisis not mentioned in the passage.

c. This is false information.

This answer is correct.

a. This is the job of the Assembly Room.b. This is the job of the Assemlby Room.

3. b. This answer is correct. The assembler must make a goodglue seam. A good glue seam requires glue that is keptwithing the temperature specifications.

a. Workers in Receiving do this job.b. This was not mentioned in the passage.

4. b. This answer is correct.

a. This was not mentioned in the passage.b. This was not mentioned in the passage.

5. b. This answer is correct. The worker must weigh the patternsafter dipping and after drying; therefore, the workermust be able to read weighing scales.

a. This was not mentioned.b. The Zahn cup measures paint thickness. It was not

mentioned in class.

6. b. This answer is correct.

a. This is incorrect.b. This is incorrect.

7. b. This answer is correct.

a. Green Sand molds use bonded sand.

8. a. This answer is correct.

b. Even though the EPS castings have lost extra metal,this is not why they are called "lost foam".

c. Some EPS castings have to be ground; therefore, thisanswer is incorrect.

9. b. This answer is correct.

a. This is false information.c. This is not mentioned in the passage.

230

WHY EPS CASTINGS ARE BETTER

EPS castings have a very good surface finish. EPS castingshave cleaner surfaces and cleaner inside spaces.

EPS casting have better detail and dimensional accuracy.Dimensions are the measurements of length, width, and thickness ofa casting. EPS casting dimensions are easier to control than GreenSand.

EPS castings have fewer defects than Green Sand. Because EPSsand does not have binders and the patterns do not have cores, EPScastings do not have gas porosity defects. The unbonded sand keepsthe EPS casting from having shrinkage defects.

EPS casting have a lower finishing cost. The castings do nothave extra metal on them that has to be ground off. The castingsdo not require as much machining es Green Sand castings.

THE FUTURE OF EPS

Today Robinson is a leader in the EPS process. They make moregrey iron castings by lost foam than any other independent foundryin the world. Foundry owners from 22 different countries have cometo Alex. City to see the EPS process. The future looks bright.

***ANSWER THESE QUESTIONS***

DIRECTIONS

Fill in the blanks with words from the passage.

The first one is done for you.

1. EPS castings generally have better surface finishand have cleaner spaces.

2. Castings measurements of length, width, and thickness arecalled

3. Cleaning roow cost are with EPS because extradoesn't have to be ground off.

4. EPS castings don't havedefectsbecause the sand doesn't have binders.

231

5. Because EPS castings don't have cores, the castings do not havegas porosity

6. Because EPS sand is , EPS castings do not haveshrinkage defects.

7. EPS casting are easier to control than GreenSand.

8. Robinscql makes more "lost foam" castings than any otherircial.:-ident foundry in the

:.-:.MATCH THE WORDS TO THEIR MEANING***

DIRECTIONS

Put the amber of the word in front of the correct meaning.

1. gape Holds the cluster for the iron pouring

2. eimension Keeps iron from touching the sand

3. Receiving another name for EPS

4. Lost Foam groups of EPS patterns glued together

5. coating Evaporated Polystryene System

6. EPS hot melt adhesive

7. EPS pattern length, width, thickness of a casting

8. Robinson They weigh EPS patterns

9. flask Makes more EPS castings than anyone else

10. cluster Made out of Expandable Polystyrene Beads

CHECK YOUR ANSWER ON THE NEXT PAGE

232

FILL IN THE BLANKS

1. surface, inside

2. dimensions

3. lower, metal

4. gas porosity

5. defects

6. unbonded

7. dimensions

8. world

MATCHING

9

54

1061

2

3

87

ANSWERS

2 3 3'

You have completed the lesson.

Go on to the next page to retake the quiz you started thisbooklet, or go back and review the lesson before taking thequiz.

234

EPS - -Quiz 2

DIRECTIONS

Circle the answer you think is correct.

1. What does EPS mean?

a. Exothermic Polystyrene Styrofoamb. Expandable Process Styrofoamc. Evaporated Polystyrene System

2. How old is the "lost foam" process?

a. over 3000 years oldb. over 300 years oldc. over 30 years old

3. What are EPS patterns made of?

a. excess styrofoamb. expandable polystyrene beadsc. iron, aluminum, plastic, or wood.

4. Which of the following is an important part of the foamassembler's job?

a. Making a strong glue seam between the pattern andthe gating.

b. Making sure the pattern is completly covered bythe coating.

c. Setting the sprue correctly.

5. Why are EPS patterns dipped in a coating?

a. To keep the styrofoam from melting.b. To eliminate mold wall movement.c. To keep the iron from touching the sand when the

iron is poured.

2'

6. Why is EPS called "Lost Foam"?

a. Because EPS castings have fewer defects and have"lost" the need for grinding.

b. Because the pattern evaporates when the molteniron hits it.

c. Because EPS castings have "lost" the extra natalsuch as the parting line.

7. Why are EPS castings better than Green Sand?

a. Tolerance bands are higher.b. Better dimensional accuracyc. Sand binders eliminate gas defects.

CHECK THE NEXT PAGE FOR THE CORRECT ANSWER TO THE QUIZ

ANSWERS

1. c

2. c

3. b

4. a

5. c

6. b

7. b

JOBS

A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

LESSON 7GREEN SAND

ROBERT E. STONE WRITTEN BY:PROJECT DIRECTOR, BETH MAXWELL,205 234 6346 EXT.6217 INSTRUCTOR

c-,-- ,, 205 329 8481 EXT.814....,;.)

WORD LIST

1. Pallet line

2. Shake-out

3. Castings

4. Sand

5. Core

6. Mold

7. Green Sand

8. EPS

9. Fins

10. Product

PALLET LINE

2

PALLET LINE READING

Frank works in the Pallet Line or green sand process. He

works on shake-out line. All the castings come out of shake-

out machine for Frand to remove excess sand. The core of

castings also comes out of the machine. The sand holds

together to form mold of casting. The green sand process is

done through pallet line. The process uses sand other than foam

like in EPS. Fins must be added to castings for finished product.

The product must be done completely to be taken by the customer.

Circle the following words in the reading:

1. Pallet line2. shake-out3. castings4. sand5. core6. mold7. Green Sand8. EPS9., fins

10. product

2-'110

Fill in missing words:

Frank works in the -- He

works on - . All the

come out of - machine for Frank to remove

excess . The of also

comes out of machine. The __ __ __ __ holds together to form

of . The

process is done through

The process uses other than foam as in .

must be checked on. The

must be done completely to be taken by the

customer.

24i

A__ _1_ t i e c r

pall e re

p le_ 1 co

pal 1_ c e

let ne o epall t 1 ne or

sh k - u

s a e- ut

sha - t

sh e- ut

sha -ou

m -1

Id

mo

m d

ting E

c t g E S

c s i g S

ting p ____

of

cas P S

s n F N

nd

sa

SAN

2 4

IN

1. at2. b d

3. j k

4. x z

5. a n

6. f g

7. o p

8. h j

9. p r

10. v w

11. a b

12. j k

13. d f

14. x y

15. g h

16. s u

17. n p

18. e f

19. h i

20. t u

fn:Beth\alpha

PREACTIVITY FOR A to 8

el 4 ..N

4.. , Ta

1. FLASK

2. ACCIDENT

3. CORE

4. SAND

5. PATTERN

1. MOLD

2. SLAG

3. FIN

4. EPS

5. CASTING

1. DEFECT

2. SCRAP

3. BP

4. SAFETY

5. HAMMER

FN:BETH\ALPHA2

PREACTIVITY FOR AIHABETICAL ORDER

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

FIND THE DEPARTMENTS ON THE MAP

1. Personnel and Lab

2. Supply

3. Cleaning Room

4. Shipping

5. Pattern Shop

6. Iron Melting

7. EPS

8. Green Sand

9. Disa

10. Core Room

11. Storage

12. Storage

13. Maintenance

14. Security

Furx?...1cioclibt50

aJ (rD

(7,

Le9.);

c'D

JOBS

A PARTNERSHIP BETAEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

LESSON 8EPS-1

ROBERT E. STONE, WRITTEN BY:PROJECT DIRECTOR BETH MAXWELL,205 234 6346 EXT 6217 INSTRUCTOR

205 329 8481 EXT 81C) ,

-1 .3

1. EPS

2. PROCESS

3. FOUNDRY

4. CASTING

5. FOAM

6. POURED

7. SAND

8. FLASK

9. IRON

10. DUMP

EPS WORD LIST

249

EPS READING

Quinton works in EPS at Robinson Foundry. EPS is

the process in the Foundry that uses styrofoam to make

castings. The foam is placed inside the flask. The sand

is poured over the foam from an automatic sand dump. After the

dump packs the sand, then the iron is poured through a sprue

into the foam. The foam evaporates when iron is poured

into the flask.

Circle these words in the reading:

1. EPS2. process3. Foundry4. casting5. foam6. poured7. sand8. flask9. iron

10. Quinton11. dump

EPS READING

works in is the

in thethat uses styrofoam

to make The is placedinside the

over the

The is

from an automatic dump. Afterthe packs the then the is

through a sprue into the. The

frame exaporates when the is

into the

Fill in the following words:

1. EPS2. process3. Foundry4. casting5. foam6. poured7. sand8. flask9. iron

10. Quinton11. dump

2

EPS

Fill in the missing letters:

P c stnP S c t g

S s i

E a t n- -F ud y

F d

o n r

_ n d

d

ca _ _ _____ ____ g

o r d

r

P__ __ __ __ d

p u e

p____ r

c is r

252

s

PREACTIVITY FOR A to Z

1. st2. b

3. j k4. x

5. m n

6. f g7. o p8. h

9. p

10. v w

11. a b12. j k13. d14. x y15. g h16. s17. n18. e f19. h i20. t u

PREACTIVITY FOR ALPHABETICAL ORDER

1. FLASK 1.

2. ACCIDENT 2.

3. CORE 3.

4. SAND 4.

5. PATTERN 5.

1. MOLD 1.

2. SLAG 2.

3. FIN 3.

4. EPS 4.

5. CASTING 5.

1. DEFECT 1.

2. SCRAP 2.

3. BP 3.

4. SAFETY 4.

5. HAMMER 5.

0 '1 'Y4-4p

Qj

Qti

Cf

1

I r,

JOBS

A PARTNERSHIP BETAEEN EDUCATION AND I OUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

LESSON 9EPS-2

ROBERT E. STONE, WRITTEN BY:PROJECT DIRECTOR BETH MAXWELL,205 234 6346 EXT 6217 INSTRUCTOR

205 329 8481 EXT 81rl "-.1

"-e v 1

EPS READING-2 WORD LIST

1. EPS

2. foam

3. department

4. pattern

5. sprue

6. sand

7. iron

8. cluster

9. flask

10. assembly

EPS READING-2

In EPS the styrofoam patterns are ordered from othercompanies. The patterns are delivered to assembly at

Robinson Foundry. In assembly the pieces are glued togetherand then sent up to EPS department. In the department the foamis dipped in a mixture to keep the sand and foam separate.

Then the foam is put in a cluster to place in the flask. Acone shaped foam piece called a sprue is glued to the

cluster. The sprue is attached to the cluster before

sand is dumped in the flask. After the sand is packed, thenthe iron is poured into the sprue aad runs into the foam. Thefoam evaporates as soon as the hot iron hits it. The castingis formed by the pattern made in the sand.

Circle the following words in reading:

1. EPS2. foam3. department4. pattern5. sprue6. sand7. f.ron8. cluster9. flask

10. assembly

EPS READING-2

In the styrofoam areordered from other companies. The aredelivered to at Robinson Foundry. In

the pieces are glued together and then

sent -.Ap to. In the

the is dipped in a

mixture to keep the and separate. Thenthe is put in a to place in the

. A cone shaped piece called a

is glued to the. The

is attached to the before

is dumped in the. After the

is packed then the is poured into the

and runs into the. . The

evaporates as soon as the hot hits it. The

casting is formed by the made in the

EPS-2

Fill it the missing letters:

E s r e

P s u__

r

E P

S

p u

o _ m s n

f o a d

.__am n d

f_a s a

f m s d

u

e a t e t a e m -- -- --

d p r m n asebyo

a n t e 1

a sml__ __ p __ __ t n t seby

t n

t r n

c 1 tu t

p t e n 1 s e

p t cut rt t n t

2tic i

1. st2. b

3. j k4. x

5. m n

6. f g7. o p8. h

9. p

10. v w

11. a b12. j k13. d14. x y15. g h16. s17. n18. e f19. h i20. t u

PREACTIVITY FOR A to Z

riU

1. FLASK

2. ACCIDENT

3. CORE

4. SAND

5. PATTERN

1. MOLD

2. SLAG

3. FIN

4. EPS

5. CASTING

1. DEFECT

2. SCRAP

3. BP

4. SAFETY

5. HAMMER

1

PREACTIVITY FOR ALPHABETICAL ORDER

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

pa)p

4--f

_A-

gLY

1

I"ou

hdvy

JOBS

A PARTNERSHIP BETWEE\ EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON rOUNDRY, INC.1992

LESSON 10GRINDING PRODUCTION SHEET

ROBERT E. STONE,PROJECT DIRECTOR205 234 6346 EXT 6217

c") r- ki i )

WRITTEN BY:SANDRA MANN,INSTRUCTOR/COUNSELOR205 329 8481 EXT 81

1

The GRINDING PRODUCTION SHEET is used in the

Cleaning Room.

Grinders fill out this form to report the

number of castings they have cleaned. The

completed forms go to the office where the

information is put into the computer.

Read the following pages to learn how to

read and fill out a GRINDING PRODUCTION SHEET.

Ask your teacher for a blank GRINDING PRODUCTION

SHEET to use while learning about this form.

Answer any questions on your paper.

DO NOT WRITE IN THIS BOOKLET

267

The orange lines tell information about the employee

doing the work.

It is very important for the employee to write his

or her full name so the office can put the information

in the computer.

2CS

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S):

CASTING PRODUCTION TIME TIMENUMBER TOT. GROUND I TOT. SCRAP START STOP

PM4/PROD0009/061191

The GRINDING PRODUCTION SHEET is different from other

productions sheets. It has only column headings. There

are no row headings down the side.

Look at the column heading in pink. When a pallet full

of castings is placed in front of a grinding station, the

worker writes the casting number here.

1,

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:GRINDER(S):

CASTINGNUMBER

PRODUCTIONTOT. GROUND I TOT. SCRAP

TIME TIMESTART. STOP

PM4/PROD0009;061191

271

Look at TOT. GROUND in blue. TOT. stands for total.

This column shows how many good castings on each

pallet are cleaned, ground, and sent to the Finishing

Department.

Look at TOT. SCRAP in grson. TOT. stands for total.

This column shows how many defects were found and

set aside for Quality Control to inspect.

2 1 4,

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S):

CASTING PRODUCTIONNUMBER TOT. GROUND TOT. SCRAP

TIMESTART

TIMESTOP

r4, 1 t)

PM4/P RO D0009.05 1 1 91

The last two columns show how long it took the worker

to grind each pallet of castings.

Look at TIME START in yellow. The worker writes the time

he begins work on the pallet.

Look at TIME STOP in pink. The worker writes the time he

finishes the pallet.

DATE:

GRINDING PRODUCTION

SHIFT: WORK CENTER:GRINDER(S):

CASTINGNUMBER

PRODUCTIONTOT. GROUND TOT. SCRAP

TIMESTART

TIMESTOP

PM4/PROD0009:061191

Do the exercises on the following pages

to see how much you have learned about

the GRINDING PRODUCTION SHEET.

276

GRINDING PRODUCTION SHEET

DIRECTIONS: Answer the following questions about the GRINDINGPRODUCTION SHEET on the next page. Write your answers on yourpaper.

1. How many pallets did the worker complete for this day?

2. Which pallet had less than 5 castings ground?

3. Which pallet had the most scrap?

4. Which pallet had the least scrap?

5. Which pallet took the most time to grind?

6. Which pallet took the least time to grind?

CHECK YOUR ANSWERS ON THE NEXT PAGE.

4,

DATE:

GRINDING PRODUCTION

9D, SHIFT: 1 WORK CENTER:

GRINDER(S): + e r- Rc-c-SSed

CASTING PRODUCTION TIMESTART

TIMESTOPNUMBER TOT. GROUND TOT. SCRAP

3(i-60 35) /5 3 Co: to 17:c1S1

1 R I- 0 o&S .:2,A 2: lb q..5.2)1061- io -JO 5 0 10:05 JOH

4 36 0 3( I Ja:td 1 a.:-.-4?

0113- D.- (0 1:10 /:5'5)

PM 4,131:10 D0009,061 1 91

27

ANSWERS

1. 5 pallets

2. 32007-10-10

3. 121-0028

4. 32007-10-10

5. 09193-10-0

6. 436038

279

GRINDING PRODUCTION EXERCISE

DIRECTIONS: Fill out a GRINDING PRODUCTION SHEET for the followingwork.

The TOT SCRAP is not shown. You figure this by subtracting thenumber ground from the number on the pallet.

1. Beginning at 6:00, you work on 346038. You have 18 castings onyour pallet. You grind 15 castings and finish at 6:48.

2. At 6:50, you work on 905866. You have 3 on your pallet. Youget 3 ground by 7:14.

3. You begin work on 905978 at 7:30. You have 4 castings on yourpallet. You get 4 done by 7:54.

4. Work on 095F1201 begins at 8:00. There are 13 castings on yourpallet. 11 castings are ground. The castings are finished at8:54.

5. At 9:10, you begin work on 122 castings of SD-6065. Yougrind 110 and finish at 10:00.

6. At 11:00, you begin on 121-0028. There are 31 castings on thepallet. You grind 22 castings and you finish the pallet at12:42.

7. You begin work on 09234-10-0 at 12:45. There are 69 castingson your pallet. You grind 65 castings. This takes you until2:03, the end of your shift.

DID YOU REMEMBER TO SUBTRACT TO FIND THE SCRAP TOTALS?

CHECK YOUR ANSWERS ON THE NEXT PAGE

2L0

DATE:

A- 115 wcr-

GRINDING PRODUCTION

SHIFT: WORK CENTER:GRINDER(S):

CASTING PRODUCTION TIMESTART

TIMESTOP

NUMBER TOT. GROUND I TOT. SCRAP

L( (2 0 3$ 15 G:oo 6:ciS9 05 3 C6 3 6 rs-b t-7: I ci

9 6 5 q -7171- .d "7:3o "7: 5 q

( : ) ° / SF 1 20 / I 1 (2 y,.ob 545I -60G5 ( (0 I q;16 ID:10

I.1 -005? c22, 9 I(6.00 ):(tc),oq (#_. to.° 65 LA:c15- a :03

PM4/PROD0009/06 1 1 91

CONGRATULATIONS!

You have learned how to read and fill out a GRINDING PRODUCTION

SHEET.

If you have any questions, ask your teacher for help.

9 cL.44

JOBS

A PARTNERSHIP BETWEEN EDUCATION AND wUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

ROBERT E. STONE,PROJECT DIRECTOR205 234 6346 EXT 6217

LESSON 11BUILDING AND GROUNDS

WRITTEN BY:BETH MAXWELL,INSTRUCTOR205 329 8481 EXT 81

BUILDING AND GROUNDS WORD LIST

1. Building

2. Grounds

3. Foundry

4. Trash

5. Cleans

6. Safety

7. Departments

8. Pallet Line

9. Core

10. EPS

11. Cleaning

12. Materials

BUILDING AND GROUNDS-READING

Robert works on Building and Grounds at Robinson

Foundry. He emptys trash and cleans departments. He must

be careful and watch safety signs. He must do many tasks.

He reports to his supervisor, Sam Huntley, who gives him orders

for the day. He works in all departments, Pallet Line, Melt Deck,

Core Room, Cleaning Room and EPS. He sometimes must go to

special places in the Foundry to clean or put materials

away.

Circle these words in the reading:

1. Building2. Grounds3. Foundry4. trash5. cleans6. safety7. departments8. Pallet Line9. Core

10. EPS11. Cleaning12. materials

2c-5L,_

BUILDING AND GROUNDS-READING

Fill in the missing letters:

Robert works on B i and ndsat Robinson F d . He emptys and

departments. He must be careful and watch

signs. He must do many tasks. He reports to his

supervisor, Sam Huntley, who gives him orders for the day. He

works in allP

Line, Core Room, Cl Room and __ Hesometimes must go to special places in the

to of put away.

WORD LIST:1. Buildings2. Grounds3. Foundry4. trash5. cleans6. safety7. departments8. Pallet Line9. Cleaning10. EPS11. materials

E 6

BUILDING AND GROUNDS-MISSING LETTERS

FILL IN THE MISSING LETTERS:

B g

B i d c e nB d g ans

ld ng cl ns

ans

g ons s f ty

und saf__ __ __ __ -r u __ d __ - -et__

gr d a ety

gro s y

F d

Fouments

n ry ar __ m s

F u d y art isart __ __ ___

r

ndry dep a is

P t Line

P 1

a le Li

thr 11

Pal Li

r-,

BUILDING AND GROUNDS-READING

Fill in the missing letters:

c r

c re

c e

E

P

PS

EP

er 1ae r 1 s

mat ials

in is

1.

2. b

3. j k4. x

5. m n

6. f g7. o pa. h

9. p

10. v w

11. a b12. j k13. d14. x y15. g h16. s17. n18. e f19. h i20. t u

st

PREACTIVITY FOR A to Z

r.

1. FLASK

2. ACCIDENT

3. CORE

4. SAND

5. PATTERN

1. MOLD

2. SLAG

3. FIN

4. EPS

5. CASTING

1. DEFECT

2. SCRAP

3. BP

4. SAFETY

5. HAMMER

PREACTIVITY FOR ALPHABETICAL ORDER

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

2 tr 30

FIND THE DEPARTMENTS ON THE MAP

1. Personnel and Lab

2. Supply

3. Cleaning Room

4. Shipping

5. Pattern Shop

6. Iron Melting

7. EPS

8. Green Sand

9. Disa

10. Core Room

11. Storage

12. Storage

13. Maintenance

14. Security

JOBS

A PARTNERSHIP BETWEENEDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY

COLLEGE & ROBINSON

FOUNDRY, INC.

1992

LESSON 12

MOLDING PRODUCTION

SHEET

ROBERT E. STONE,

PROJECT DIRECTOR

205 234 6346 EXT 6217

292

WRITTEN BY:

SANDRA MAXWELL,

INSTRUCTOR/COUNSELOR

205 329 8481 EXT

81

The MOLDING PRODUCTION SEEET is used in Green Sand

and in EPS.

Read the following pages to learn how to read and

fill out the MOLDING PRODUCTION SHEET.

The green boxes tell when the worker starts

work and

stops work in each hour.

The yellow boxes show the hours of the shift from the

1st hour to the 9th hour.

?RO

BIN

SO

NM

OLD

ING

PR

OD

UC

TIO

ND

AT

ES

HIF

T

Nam

mim

im.

. w' MOLD

ER

DO

WN

TIM

E

TIM

ES

TA

RT

TIM

ES

TO

PT

OT

AL

TIM

EM

AC

HIN

EC

AS

TIN

GN

UM

BE

RIM

P.

MO

LDS

CLA

SS

DE

PT

HT

IME

FR

OM

TIM

ET

OT

OT

AL

TIM

E

(,,,,

,, v

.'a's

'' X/-

'

CO

MM

EN

TS

GO

OD

PO

IRO

N O

F C

HIL

LN

aY

onIn

n Sp

asIS

AM

Hot

Wel

Faun

1st

Hou

rx x

2nd

Hou

rx x

3rd

Hou

r\

4th

Hou

r

5th

Hou

r

6th

Hou

r

7th

Hou

r

eth

Hou

r

4

9th

Hou

rx x

TO

TT

OT

y___

__lip

° C

AU

SEsu

Per

usaR

s co

ovE

sas

S R

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RE

D c

oRR

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TN

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9''

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JO.:i

53S

r

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.74,

:[-

C P

OS

TE

iD

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The pink box tells the machine being used.

3 if

RO

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MO

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G P

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DA

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imm

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TIM

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AC

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IMP

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LAS

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TH

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TIM

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TO

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112

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GO

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PO

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FN

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onH

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Wit

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1st

Hou

rX x

2nd

Hou

rx

3rd

Hou

rx

4th

Hou

r

5th

Hou

rx

6th

Hou

rx

7th

Hou

rx

8th

Hou

r

9th

Hou

rx x

TO

TT

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4,44

48

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The blue box shows which casting number is molded in

each hour.

/I

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DA

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wiff

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3rd

Hou

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4th

Hou

rx

Sth

Hou

rx

6th

Hou

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The orange box shows how many impressions are on the pattern.

RO

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PR

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3rd

Hou

rx

4th

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r

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5th

Hou

r

6th

Hou

r

x x

7th

Hou

rx

8th

Hou

rx

9th

How

x x

TO

T

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A S

AN

D

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30:4

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The green box shows how many GOOD molds were made in each hour.

RO

BIN

SO

NF

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, IN

C.

MO

LDE

R

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G P

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The yellow box tells how many "PLUG-OFFS"

or bad molds were made in

each hour.

The

*shows the reason for the plug-off.

The pink box shows the plug-off

reason and the supervisor comments.

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The orange box is the total castings made from the 1st hour through

the 4th hour.

The worker found this number by multiplying the nt.ra..:_r of

impressions (the green number) times tht number of .00d molds (the

yellow number).

The worker added the totals for the first 4 hours of work and put

the answer in the orange box.

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The pink box is the total castings made from the 5th hour through

the 9th hour.

The worker found this number by multiplying the number of

impressions (the blue number) times the good molds (the orange

number).

The worker added the totals and put the answer in the pink box.

,

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The green box shows the total number of castings made for the

The worker added the totals for the 4th hour (inorange) and for

the 9th hours (in pink).

He put the answer in the pink box.

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The yellow box shows the time a worker stops work.

The orange box shows the time a worker starts back to work.

The pink box shows the number of minutes the w'rker was not at work.

337

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The blue boxes show the reason for each of the down times.

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The green box is a place for the worker to write a reason for any

down time that is not listed in the blue boxes.

RO

BIN

SO

NF

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C.

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2nd

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3rd

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4th

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x

5th

Hou

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6th

Hou

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7th

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Hou

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4/54

1300

75 3

91

Do the exercise on the next 2 pages to see how

well you have learned to read the MOLDING

PRODUCTION SHEET.

Write your answers on your paper.

Do not

write in this booklet.

MOLDING PRODUCTION SHEET

DIRECTIONS:

Answer the following questions about the MOLDING PRODUCTION SHEET filled out by

George Smith on 5-15-91.

1.

Which CASTING NUMBER has the most IMPRESSIONS on the pattern plate?

2.

Which CASTING NUMBERS have the least IMPRESSIONS

c the pattern plate?

3.

In which hour were the most MOLDS made?

How many castings were made in this hour?

4.

In which hour were the least amount of MOLDS made? How many castings

were made in this

hour?

5.

Which hour had the most PO?

What was the cause?

6.

Why was the work stopped at the following times?

4:30

7:05

10:13

11:05

7.

What was the total DOWN TIME?

8.

How many castings were made during the following

hours?

1st Hour

2nd Hour

3rd Hour

5th Hour

6th Hour

7th Hour

TURN THE PAGE AND CHECK YOUR ANSWERS

RO

BIN

SON

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1

1.

2.

3.

4. 5.

300333

63197787

The 3rd hour;

The 1st hour;

The 2nd hour;

ANSWERS

100

14

A (sand)

6.

4:30

no iron

7:04

pattern

change

10:13

Electric

Bull down

11:05

working

on pattern

7.

54

8.

1st

2nd

3rd

5th

6th

7th

hour:

14

hour:

25

hour:

100

hour:

30

hour:

192

hour:

172

,

Now that you know how to read a MOLDING

PRODUCTION FORM, do the exercise on the

next 2 pages.

Ask your teacher for a blank MOLDING

PRODUCTION FORM to use for the exercise.

Check your answers by the answer key at

the end of the book.

THE MOLDING PRODUCTION SHEET

DIRECTIONS:

Fill in a production sheet with the following information about each job.

Use your own name, your shift, and today's date.

THE FIRST JOB

You start work at 4:00.

You work on the Hunter today.

The first job is on CASTING NUMBER

901504.

This casting has 2 impressions.

This casting is made with 25 CLASS IRON.

Fill in the rest of the sheet using the following information:

1st

hour:

GOOD

MOLDS:

25

P0:

0PO

CAUSE:

0

2nd

hour:

GOOD

MOLDS:

30

P0:

0PO

CAUSE:

0

3rd

hour:

GOOD

MOLDS:

10

PO:

15

PO

CAUSE:

A

THE SECOND JOB

You start work on the second job at 7:00.

This job is on CASTING NUMBER 40162P.

This

casting has 5 impressions.

This casting is poured with 30-A CLASS IRON.

Fill in the rest of the sheet using the following information:

4th hour:

GOOD MOLDS:

55

PO:

0PO CAUSE:

0

5th hour:

LUNCH

6th hour:

GOOD MOLDS:

25

PO:

13

PO CAUSE:

B

THE THIRD JOB

You start work on the third job at 12:00 noon.

This job is on CASTING NUMBER R-153-E.

This

casting has 1 impression.

This casting is poured with 25 CLASS IRON.

Fill in the rest of the sheet using the following information:

7th hour:

GOOD MOLDS:

85

P0:

0PO

CAUSE:

0

8th hour:

GOOD MOLDS:

95

PO:

0PO

CAUSE:

09th hour:

GOOD MOLDS:

75

PO:

22

PO

CAUSE:

C

TOTALS

Add up the total molds through the 4th hour.

Add up the total molds from the 6th hour

through the 9th hour. Add up the total for the day's production.

DOWN TIME

DIRECTIONS:

Fill out the DOWN TIME side with the following information:

5:05

to

5:22

NO IRON

6:15

to

6:45

DRY SAND

10:36

to

10:55

ELECTRIC BULL DOWN

11:11

to

11:35

WORKING ON PATTERN TOTALS

Add up the TOTAL TIME for each DOWN TIME.

4,

RO

BIN

SO

NM

OLD

ING

PR

OD

UC

TIO

ND

AT

ES

HIF

T

FO

UN

DR

Y. I

NC

.11

1/11

0.1.

1111

1111

1M

OLD

ER

TIM

E

TIM

ES

TA

RT

TIM

ES

TO

PT

OT

AL

TIM

EM

AC

HIN

EC

AS

TIN

GN

UM

BE

RIM

P.

MO

LDS

CLA

SS

DE

PT

HF

CH

ILL

TIM

EF

RO

MT

IME

TO

....

TO

TA

LT

IME

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CONGRATULATIONS!

You have learned how to read and fill out the MOLDING PRODUCTION SHEET.

If you have any questions, ask your teacher for help.

JOBS

A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY,

INC.

1992

LESSON 13

FORMS

ROBERT E. STONE,

PROJECT DIRECTOR

205 234 6346 EXT, 6217

WRITTEN BY:

SANDRA MANN,

INSTRUCTOR/COUNSELOR

205 329 8481 EXT 81

A, 1

OCCUPATIONAL FORMS USED AT

ROBINSON.

To be a successful worker,

you need to know how to read and

understand occupational forms

such as charts, graphs,

tables, and

forms.

Robinson Foundry uses

many different kinds of occupational

forms every day.

Charts, graphs, tables, andforms are used to

record and store information

about the work Robinson

employees do

each day.

It is important for

you to know how to read and understand

any

occupational form that is used in

your department.

You also need

to know how to write information

on these forms.

Many occupational forms used at Robinson are in the form of a CHART.

A CHART is a way to show facts and figures

so that you can see the

information easily.

Look at the CHARTS on the next 6

pages to learn how to read occupational

charts.

371

0-1

The blue boxes tell what is

written in the boxes down below

them.

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

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e:M

achi

ne N

o.:

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e.:::

...F

rOm

-T

o::

;,N

o.C

ore

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c-ip

tiOn"

:C

ore:

:W

eigh

t,,rim

pf ::

Box

:`C

yice

itM

achi

ne: ::7

-Mad

eP

iece

sP

iece

sS

crap

Dow

nT

ime

1st

Hou

r

2nd

Hou

r

3rd

Hou

r

4th

Hou

r

5th

Hou

r

6th

Hou

r

7th

Hou

r

I-

8th

Hou

r

9th

Hou

r

37 4

PM

4/P

R00

0005

01.

1 'I.

.-

The pink boxes tell what is written in the rows

across to the right.

0.1

1..)

1I

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

I.D. N

o.C

ore

Des

crip

tion

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eW

eigh

tIm

p/B

oxsc

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ces

Pie

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-Mad

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1st

How ur

Sqi.

tith

PIO

N._

......

373

PM

4/P

RO

D00

05

el r

i

Look at the

orange box where the two lines meet.

This shows howmany pieces were made in the 5th hour.

Dat

e:S

hift:

SHE

LL

CO

RE

PR

OD

UC

TIO

N

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

I.D. N

o.C

ore

Des

crip

tion

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eW

eigh

tIm

p/x

Box

Mac

hine

Cyl

ces

Pie

ces

= ft

/Ode

Pie

ces

Scr

apD

own

Tim

e1s

tH

our

2nd

Hou

r

3rd

Hou

r

4th

Hou

r

;;.H 6t

hH

our

7th

Hou

r

8th

Hou

r

9th

Hou

r

0r)

PM

4/P

RO

D00

05

0 0

fla.

/ 0 j.

)

Now that you know how to read a CHART, do the exercises on the next two

pages.

Write your answers on

your paper.

Do not write in this booklet.

"4 00O n r- ti

SHELL CORE PRODUCTION SHEET

Look at the SHELL CORE

PRODUCTION SHEET on the next page.

Answer the

questions about that sheet.

Write the answers on

your paper.

1.

What is the CORE I.D. NO. for the work

done in the 5th hour?

2.

How many PIECES were made in the 8th hour?

3.

How many PIECES SCRAP were made in the 7th

hour?

4.

Jack went to lunch in the

hour.

5.

The machine broke down in the

hour.

6.

What is the CORE DESCRIPTION for the 1st hour?

7.

What is the CORE WEIGHT for the 4th hour?

8.

Core I.D. No. 1202963 has

IMPRESSIONS.

9.

How many MACHINE CYCLES were run in the 2nd hour?

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

Nam

e:M

achi

ne N

o.:

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eF

rom

- T

oC

ore

I.D. N

o.C

ore

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crip

tion

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eW

eigh

tIm

p/B

ox 2

(M

achi

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y Ic

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s=

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3 05

PM4/

PRO

D00

05

Now that you know how to read a

CHART, let's learn how to fill out to

a SHELL CORE PRODUCTION SHEET.

Get a blank SHELL CORE PRODUCTION SHEET from

your teacher.

Turn the page to see how

you fill out this form.

301

Look at the IIII lines.

This is the place for the DATE, the

SHIFT, the

FULL NAME, and the Shell Core MACHINE NUMBER.

If you do not put your FULL NAME

on the line,

the computer will not give

you credit for your work.

Fill in your practice sheet with the following:

DATE:

put today's date

SHIFT:

1ST

NAME:

write your own name

MACHINE NO.:

400

SHE

LL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hith

amm

Nam

eim

mum

nsia

mem

Mac

hine

No

Tim

eF

rom

- T

oC

ore

I.D. N

o.C

ore

Des

crip

tion

Cor

eW

eigh

tIm

p/B

oxx

Mac

hine

Cyl

ces

Pie

ces

=M

ade

Pie

ces

Scr

apD

own

Tim

e1s

tH

our

2nd

Hou

r

3rd

Hou

r

4th

Hou

r

5th

Hou

r

6th

Hou

r

7th

Hou

r

8th

Hou

r

9th

Hou

r

PM

4/P

RO

D00

05

Look at the blue box.

This shows the time work begins andends for each

hour.

The numbers show how this column should be filled

in for the

first shift.

Copy the numbers on your practice sheet.

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

I.D. N

o.C

ore

Des

crip

tion

Cor

eW

eigh

tIm

p/B

ox74

Mac

hine

Cy

Ices

Pie

ces

-1

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sS

crap

Dow

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1st

Hou

r11

;(71

.) -

5! 4

1)

2nd

Hou

r,..

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-3 -

(0. 6

1)

3rd

Hou

r6:

J6 -

/-16

4th

Hou

r76

1,(.

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-1

5th

Hou

r8:

" -

1:61

3

6th

Hou

rc.

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I °*

au

7th

Hou

r1J

: i4

-1 I

ta)

8th

Hou

r1

1.#0

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v.,

9th

Hou

rID

;efu

-i:06

PM

4/P

RO

D00

05

3C8

The orange numbers are the CORE I.D.

NO.

The green words are the CORE DESCRIPTIONS.

These numbers and words are

always filled in by the leadman.

Copy them on your practice sheet.

A is

0L

' IV40

1

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

I.D. N

o.

R '''::

CO

re''.

..,'

Des

crip

tion

"

Cor

eW

eigh

tIm

p/B

oxz

Mac

hine

Cy

Ices

Pie

ces

=M

ade

Pie

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Scr

apD

own

Tim

e

ist

Hou

r5

5'1

'6)9

(-[

Gl

(-le

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v-)

2nd

Hou

r.

/i1

3rd

Hou

r

4th

Hou

r1ar

t ,35

'75

1

_i__

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ci

5th

Hou

r)%

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6th

Hou

r

,

(

.

7th

Hou

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our

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1t

9th

Hou

r.

k/,

402

PM

4/P

RO

D00

05

403

The yellow box shows the COREWEIGHT.

The worker weighs the firstcore he makes and writes the amount in this

column.

Put these core weights on

your practice sheet:

1st

hour:

9.5

lbs.

2nd

hour:

11

3rd

hour:

11

4th

5th

hour:

hour:

1.5

lbs.

6th

hour:

7th

8th

hour:

hour:

3 lbs.

9th hour:

L.0

4.1

) ' ljj

Dat

e:S

hift:

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

I.D. N

o.C

ore

Des

crip

tion

Cor

eW

eigh

tIm

p/B

oxx

Mac

hine

Cyl

ces

Pie

ces

=M

ade

Pie

ces

Scr

apD

own

Tim

e

1st

Hou

r

2nd

Hou

r

3rd

Hou

r

4th

Hou

r

5th

Hou

r

6th

Hou

r

7th

Hou

r

8th

Hou

r

9th

Hou

r

L7.0

PM4/

PRO

D00

05

(10

The pink box shows the number

of IMPRESSIONS in the

core box.

Put these IMPRESSIONS

on your practice sheet:

n 8

1st hour:

12nd hour:

13rd hour:

14th hour:

2

5th hour:

2

6th hour:

2

7th hour:

18th nour:

1

9th hour:

1

40

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

I.D. N

o.C

ore

Des

crip

tion

Cor

eW

eigh

tM

achi

neC

y Ic

esP

iece

s- M

ade

Pie

ces

Scr

apD

own

Tim

e

1st

Hou

r

2nd

Hou

r

3rd

Hou

r

4th

Hou

r

5th

Hou

r

6th

Hou

r

7th

Hou

r

8th

Hou

r

9th

Hou

r

4 I

0P

M4/

PR

OD

0005

The blue box shows the number

of MACHINE CYCLES.

The worker writes howmany times he runs his machine

a full cycle

and makes one or more

cores.

Put these MACHINE CYCLES

on your practice sheet:

1st hour:

35

2nd hour:

34

3rd hour:

32

4th hour:

67

5th hour:

34

6th hour:

60

7th hour:

25

8th hour:

35

9th hour:

31

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

I.D. N

o.C

ore

Des

crip

tion

Cor

eW

eigh

tIm

p/B

ox x

Mac

hine

Cy

Ices

Pie

ces

= M

ade

Pie

ces

Scr

apD

own

Tim

e

1st

Hou

r

2nd

Hou

r

3rd

Hou

r

4th

Hou

r

5th

Hou

r

6th

Hou

r

7th

Hou

r

8th

Hou

r

9th

Hou

r

4 4

4:15

PM

4/P

RO

D00

05

The green box shows the number

of PIECES MADE in each hour.

The worker multiplies the

orange numbers under IMP/BOX times the blue

numbers under MACHINE CYCLES.

He writes the answer in the

yellow box

under PIECES MADE.

The 1st hour hour and the 4th hour

are filled in to

show you how to do this.

Fill in the rest of the PIECES

MADE column on your practice sheet.

Lt i

I

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

I.D. N

o.C

ore

Des

crip

tion

Cor

eW

eigh

tIm

p/B

ox74

Mac

hine

Cyl

ces

'Pis

ces

:11

'0W

e'P

iece

sS

crap

Dow

nT

ime

1st

Hou

rI

353-

--2n

dH

our

3rd

Hou

r

4th

Hou

rc-

-,(0

71

3Li-

5th

Hou

r,

6th

Hou

r

7th

Hou

r

8th

Hou

r

9th

Hou

r

(-1

L,

0L

1.19

PM4/

PRO

D00

05

The pink box shows the number of PIECES

SCRAP.

At the end of each hour the worker writes thenumber of scrap pieces he

made.

Put these SCRAP numbers on

your practice sheet:

1st hour:

02nd hour:

13rd hour:

3

4th hour:

10

5th hour:

46th hour:

67th hour:

08th hour:

09th hour:

0

H2O

4112

1

SHE

LL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

I.D. N

o.C

ore

Des

crip

tion

Cor

eW

eigh

tIm

p/B

oxx

Mac

hine

Cyl

ces

Pie

ces

- Mad

e

---

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get.

Scr

ap=

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own

Tim

e1s

tH

our

2nd

Hot

.-

3rd

Hou

r

4tn

Hou

r

5th

Hou

r

6th

Hou

r

7th

Hou

r

8th

Hou

r

9th

Hou

r

PM

4 /P

RQ

D00

05

2 2

The blue box shows the DOWN TIMES.

The worker writes in the amount of time he is not running hismachine.

He also writes the reason for the DOWN TIME.

The first DOWN TIME is

filled in to show you how to do this.

Put these DOWN TIMES

5th hour:

7th hour:

on your practice sheet:

30 min lunch

15 min power off

TURN THE PAGE TO SEE IF YOUR PRACTICE SHEET IS CORRECT.

2 4

2 5

SH

ELL

CO

RE

PR

OD

UC

TIO

N

Dat

e:S

hift:

Nam

e:M

achi

ne N

o.:

Tim

eF

rom

- T

oC

ore

E.D

. No.

Cor

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escr

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ght

Imp/

Box

xM

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sS

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Dow

nT

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1st

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r

2nd

Hou

r

3rd

Hou

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PP

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4th

Hou

r

5th

Hou

r

6th

Hou

r

7th

Hou

r

8th

Hou

r

9th

Hou

r

PM

4/P

R00

0005

SHE

LL

CO

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PR

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UC

TIO

N

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r S

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44/P

RO

D00

05

Get another blank Shell Core Production Sheet.

Turn the page and read about another day ill the career of Jack Doss.

Fill in your blank sheet with Jack's work.

If you need to, look

back in the booklet for help in doing this exercise.

1st Hour through 3rd Hour

START WITH THE 1ST HOUR AND PUTTHESE NUMBERS ON THE SHE1.2:

Jack starts

work at 5:00 on a 400 machine.

The first job is Core I.D. No.

5267997.

The leadman tells Jack towrite "Body" under the description.

The core

weighs 4.02 pounds.

The core box has 1 impression.

1st hour:

2nd hour:

3rd hour:

Machine cycles:

22

Scrap:

1

Machine cycles:

23

Scrap:

0

Machine cycles:

23

Scrap:

0

4t-1 Hour through 6th Hour

START WITH THE 4TH HOUR AND PUT

THESE NUMBERS ON THE SHEET:

The 4th

hour starts with a "body" core

with the I.D. No. of 1273574/01.

The

core box has 2

impressions.

It weighs 1.5 pounds.

4th hour:

5th hour:

6th hour:

Machine cycles:

67

Scrap:

0

Machine cycles:

65

Scrap:

4

Machine cycles:

25

Scrap:

5

7th Hour through 9th Hour

START WITH THE 7TH HOUR

AND PUT THESE NUMBERS ON THE

SHEFr:

The 7th

hour starts with a Body core

with the I.D. No. 5253741/01.

The core

weights 30 pounds.

There is 1 impression in the core

box.

7th hour:

8th hour:

9th hour:

e 0

0

Machine cycles:

16

Scrap:

0

Machine cycles:

21

Scrap:

3

Machine cycles:

18

Scrap:

5

r").

DID YOU REMEMBER TO MULTIPLY

THE IMPRESSIONS TIMES THE CYCLES TO

FIND THE NUMBER OF PIECES MADE?

Down Time

Jack had the following Down Times.

7:15 to

7:25...10

10:00 to 10:30...30

12:07 to 12:23...16

Put these times on the sheet.

minute break

minute lunch

minute power off

LOOK AT THE NEXT PAGE AND SEE IF

YOUR SHEET IS CORRECT!

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PM4/

PRO

D00

05

CONGRATULATIONS!

You have learned how to read and fill out one of the OCCUPATIONAL FORMS

used at Robinson Foundry.

If you have any further questions, ask your teacher.

r) r

")c1

. J c

3zr

., 3

JOBS

. A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

ROBERT E. STONE,PROJECT DIRECTOR205 234 6346 EXT 6217

LESSON 14GRINDING PRODUCTION SHEET

WRITTEN BY:BETH MAXWELL,INSTRUCTOR205 329 8481 EXT 81

GRINDING PRODUCTION SHEET

The grinding production sheet is used in the cleaning

room to keep a count of pieces ground. It is important to the

worker to keep up with each number every hour.

In this booklet we are going to attempt to learn to

find the parts of a grinding production sheet. The worker

will learn to find the part by first coloring the part,

next he will learn to fill in the part of the sheet.

Turn to the next page to learn about the first part

of the grinding production sheet.

The Date is placed at the top of the grinding

production sheet. Color Date blue.

4 42

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S):

CASTINGNUMBER

PRODUCTIONTOT. GROUND TOT. SCRAP

TIMESTART

TIMESTOP

.443

PM4/PR000300/061191

Fill in the date on each of the following sheets:

1. Date: 3/13/92

2. Date: 1/11/92

3. Date: 2/10/92

4. Date 1/17/92

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S): .-

CASTINGNUMBER

. PRODUCTION TIMESTART

TIMESTOP

-

-_

TOT. GROUND TOT. SCRAP

. . . :I

.

-

,

..

.

.

I t: . .It

1

.. .

.

.

..

' .. , .

.

.

-.

. . .

..

.

. .

..

. . .. .

.

.

.

.

.

.

1.

. .

.

-. - -

. .

....,

. . ...-

:

. : .

..

.. -

.

. .

.. .

' .

.. .

.

..,

.

-. .

445 -

PIA4/PRO000391061 tat

The shift is placed at the top of each sheet.

Color the shift red:

e .1 el.

DATE:

GRINDING PRODUCTION

SHIFT: WORK CENTER:

GRINDER(S):

CASTINGNUMBER

PRODUCTION TIMESTART

TIMESTOP .

TOT. GROUND TOT. SCRAP

. .

.

. .

:tic

t.

.

.

.

.. . .

_

...

. .

-. . .

.

.

.,

.

.

.

.

..

.. .

.

.

.

.

1.

. . . .

..

_ .

. - .

-

.

. .

._...

.

.

.

.

.

-. .

.

.

'-

.

.

..

. .

..

_.

.

447rm4/pR00000gi06l 101

Fill the shift in for each sheet:

1. Shift: 1st

2. Shift: 2nd

3. Shift: 3rd

4. Shift: 2nd

x

DATE:

GRINDER(S):

GRINDING PRODUCTION

SHIFT: WORK CENTER:

CASTINGNUMBER

PRODUCTIONTOT. GROUND I TOT. SCRAP

TIMESTART

TIMESTOP

t

ti

44:-) PA44/PR000000/001191

In the cleaning room there are different areas for each

grinders. These are called work centers. Color work center on the

sheets-yellow.

t: 7 r)

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:. .

GRINDERS):

CASTINGNUMBER

PRODUCTION#

TIMESTART

TIMESTOPTOT. GROUND TOT. SCRAP

I

i.

..i.1

r

.

.

- ...

.. 4..

.

. 451PL14/PR000009/061 a f

Also in the cleaning room there are many different kinds

of grinders. Look at the top of the sheet and color the

word grinders-purple.

I

. . .

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S):

CASTINGNUMBER

PRODUCTIONTOT. GROUND

TIME TIMETOT. SCRAP START STOP

453pm4fpFl00000010e1 191

. p

In working with castings, all castings have a number.

The numbers are marked somewhere on the casting. Color column

marked casting number-black.

Now fill in the following casting numbers on the other sheet:

1. 56044

2. 40424

3. 24816

4. 06F141000

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S):

CASTINGNUMBER

PRODUCTIONTOT. GROUND TOT. SCRAP

TIME TIMESTART STOP

PM 4/10 RO 00039/061 1 1

4 rr

ToT. ground means

grinder grinds. Color

the total number of castings that

ToT. ground' on your sheet-green.

Z. 7"-0

4

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S):

PRODUCTION TIME

TOT. GROUND TOT. SCRAP START

'57 PM4/PROD:030/01111111

On each line under ToT. ground the grinder

writes the number ground of that casting number. Please

fill in on each line each of the following numbers

ground:

1. 525

2. 200

3. 100

4. 225

//

4

GRINDING PRODUCTION.

DATE: SHIFT: WORK CENTER:

GRINDER(S):

CASTINGNUMBER

. PRODUCTION TIMESTART

TIME -

STOPTOT. GROUND TOT. SCRAP

. . .

.

.. . .

. . i,.

.

.

. ...

.

. ..

. .. ... : .

.

..

.-

.

. .

..

.

. .

.

.

.

.

. .

-1.

..

..

. ..

.

-

.

.

.

.

.

. .

...

.

.

. .

. .

.

.

. . .. .

*-.

. ..

459PIA4(PRO00009/091191

Tot. scrap means number that was no good in

Tot. ground. These must be remelted. Color Tot. scrap column on

the following sheet-orange.

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S):

CASTINGNUMBER

PRODUCTIONTOT. GROUND TOT. SCRAP

TIMESTART

TIMESTOP

t

PIA4/PRO03000/061 19$

4 61

On each line under Tot. scrap are filled in the number

of scrap the grinder finds each casting number. PLease fill in

each number on each line under Tot. scrap:

1. 10

2. 25

3. 40

4. 60

Ccd..-1

DATE:

GRINDING PRODUCTION

SHIFT:

GRINDER(S):

WORK CENTER:

CASTINGNUMBER

PRODUCTION . TIMESTART

TIMESTOPTOT. GROUND TOT. SCRAP

. :.

.

%

..

..

.. .. ...

. ...

.

. .

.. .

. .

.

*-1.

. . .

..

.

.

...

. .

......

.

...

. .

.

.

.

. .

.

.

. -.

. . . . -,

..

..

463 P144/PROCC00010111 191

All time on sheets must be kept, Time start means

the time you begin to work on each casting. Color Time start

column-pink.

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S):

. 465PM4/PR000000/061 tat

. . . . . .

On each line under Time start the grinder is to place

the time he begins to work on each casting. On each line

under Time start please fill in the following times:

1. 4:00 A.M.

2. 5:00 A.M.

3. 6:00 A.M.

4. 8:00 A.M.

DATE:

.

GRINDING PRODUCTION

SHIFT: WORK CENTER:

GRINDER(S):

CASTINGNUMBER

PRODUCTION TIMESTART

TIMESTOPTOT. GROUND TOT. SCRAP

. .

.

..

. . ..

.

..

. : .. ,

.

. . ..

. .

. ..

.

.

. .

.

... .

I..

.

.

.

.

.' .

. . .

..,.

. .

.0..

. .

.

. .

. .

.

. s.

.'.

. .,

I

PM4/PR000030/061121

Time stop means the time the grinder stops has grinding

on a certain casting number. Color time stop column-brown.

GRINDING PRODUCTION

DATE: SHIFT: WORK CENTER:

GRINDER(S):. :

CASTING . PRODUCTION

NUMBER TOT. GROUND TOT. SCRAP

TIME TIMESTART STOP

PA44/PR0000002/061 I i 5

On each line under Time stop each grinder must

place the time he stops. Please fill in the following times

on each line:

1. 5:00 A.M.

2. 6:00 A.M.

3. 7:00 A.M.

4. 9:30 A.M.

wt a

DATE:

GRINDING PRODUCTION.

SHIFT:

GRINDER(S)::

WORK CENTER:

CASTINGNUMBER

PRODUCTION TIMESTART

TIMESTOP

TOT. GROUND TOT. SCRAP

.

..

. . . . . .

.

.

. .. .

. ... ..

.

..

..

. ...

.

.

1.

.

_

. .

.

...

.

. .

. ._

.

.

.

.

.

' .

. ..

.

.

.

...

4 71PM4/PRO0:009/0d1 191

Now let's try filling out all the material on the grinding

production sheet. Fill in the following items on the sheet:

1. For casting number 09SF1112, fill in total amount

ground 85 with total scrap of 18. The grinder started grinding

at 5:00 A.M. and stopped at 6:15 A.M. Fill in the grinding

production sheet.

2. Casting number 08EG2233 was started at 9:00. A.M. and

stopped at 10:15 A.M. There were 35 ground and 8 scraped.

Fill in the grinding production sheet.

GRINDING PRODUCTION.

DATE:SHIFT: WORK CENTER:

GRINDER(S):

ICASTINGNUMBER

PRODUCTIONTIME

STARTTIMESTOP

TOT. GROUND TOT. SCRAP

:1

.

.

. Ia

.

.

.....,

,.(,

.

- -

. .

- .

. %

PM4/1MOD3C091091 191

f

JOBS

A PARTNERSHIP BETWEEN EDUCATION AND INDUSTRY

CENTRAL ALABAMA COMMUNITY COLLEGE & ROBINSON FOUNDRY, INC.1992

ROBERT E. STONE,PROJECT DIRECTOR205 234 6346 EXT 6217

LESSON 15RF VOCABULARY

474

WRITTEN BY:BONNIE RASMUSSEN,CURRICULUM CONSULTANT205 329 8481 EXT 81

Contents in this Learning Package

RF Vocabulary (for early readers)

1. Pretest

Trainee is given list of pairs of words. Instructor reads one wordof each pair, which the trainee is to circle.

2. Hear-and-see exercise

Trainee listens to an audio tape which reads the list of vocabularywords, and then reads sentences using the vocabulary words.Trainee 'reads along' on with cards.

(Trainee is given list of vocabualry words to take home.)

3. Alphabetizing exercise (trainee can refer to master list ofvocabulary words)

Trainee draws lines to show correct alphabetical order of a printedlist of vocabulary words.

4. Matching exercises

a. Trainee draws line from each vocabulary word to itsmatch, choosing from a pair of words in each case.

b. Same as 4a, but more difficult because of similarity ofpaired words.

5. Underlining exercises

a. Trainee underlines the vocabulary words in familiarsentences.

b. Same as 5a, but more difficult because sentences aremixed up.

6. Fill-in-the-blank exercises

a. Trainee fills in vocabulary words which have been leftout of familiar sentences.

b. Same as 6a, but more difficult because sentences aremixed up.

4'11--41)

7. Narrative exercises (after listening to audio tape)

a. Trainee finds and circles vocabulary words in narrative

paragraphs.

b. Trainee fills in vocabulary words in cloze exercise.

c. Trainee answers multiple choice questions based.

8. Post test (same as pre test)

4' 6

Pre test and Post test

ant1.

Alex City

2.

3.

4.

5.

6.

7.

8.

9.

boy

BP Machine

Coca Cola

core

Dadeville

DANGER

EPS

elephant

foundty

football

green

green sand

heat

Hardee's

IRS

iron

July10.

January

CI 7'7"

11.K -Mart

Kentucky Fried Chicken

lost12.

lost foam

13.McDonald's

mold

No Smoking Area14.

N Street

OK15.

October

.

pay check16.

pattern

quality control17.

quiet zone

18.

19.

Robinson - Bodine

Robinson Foundry

STOP

Saturday

telephone20.

taxes

478

21.

22.

23.

24.

B Street

U Street

V-8 engine

vegetables

Wal-Mart

wildcats

x-ray

x-rated movie

you25.

yes

26.

.

zebra'

zero

C2. Vocabulary List

A Alex CityB BP machineC core 3

D DANGER VE EPSF foundry

G green sand IH heat S

1 iron f

J July I°

K Kentucky Fried 0Chicken

L lost foam /2-

M McDonald-s 13N No Smoking Area itO OK 15

P patternQ quality control I/R Robinson Foundry 6

S STOP //

T taxes 2,0

II u Street 21

2V-8 engiAe 2W Wal-Mart -1

X x-ray z I'

Y you 2SZ zero 2,4-

Co

2. Sentences Using Vocabulary Words

I live in Alex City.I work on the BP Machine.Run a core on this job.

The sign says 'Danger'.I work in the EPS Department.I work in a foundry.

I iork on the Green Sand line.We heat the iron.We heat the iron.

We eat fried chicken on July 4th.We eat Kentucky Fried Chicken on July 4th.I work on the lost foam process.

We eat at McDonald's.McDonald's has a No Smoking Area.It's CK to smoke in the parking lot.

The pattern number is 346036.I work in the Ouality Control Department.I work at Robinson Foundry.

The sign says 'STOP'.You can't stop taxes.The sign says 'U Street'.

That Ford has a V-8 encine.That Ford is parked outside Wal-Mart.Get an x-ray at the Alex City Hospital.

You can't stop taxes.Five, four, three, two one, zero.

/ °I

e

C.

3. Alphabetizing exercise

Alex CitycoreBP machine

EPSfoundryDANGER

heatgraen sandiroa

Kentucky Fried Chickenlost-foamJuly

McDonald'sOKNo Smoking Area

Robinson Foundryquality controlpattern

STOPV Streettaxes

V-8 enginex-rayWal-Mart

zeroyou

L7, ric_s

4a. Matching

ant1. Alex City

Alex City

boy2. BP Machine

BP Machine

Coca Cola3. core

core

Dadeville4. DANGER

DANGER

EPS5. EPS

elephant

foundry6. foundry

football

green7. green sand

green sand

heat8. heat

Hardee's

IRS9. iron

iron

July10. July

January

K -Mart11. Kentucky Fried Chicken

Chicken Kentucky Fried Chicken

12. lost foaia

13. mold

14. .No Smoking Area

15. OK

16. pay check

17. quality control

18. Robinson -Bodine

19. STOP

20. taxes

lost

lost foam

McDonald's

mold

No Smoking Area

N Street

OK

October

pay check

pattern

quality control

quiet zone

Robinson - Bodine

Robinson Foundry

STOP

Saturday

telephone

taxes

n4

B Street21. U Street

U Street

V-8 engine22. V-8 engine

vegetables

Wal-Mart23. Wal-Mart

wildcats

x-ray24. ..x -ray

x -rated

you25. you

gun

zebra26. zero

zero

4b. Matching

apple pie1. Alex City

Alex City

Coke machine2. BP Machine

BP Machine

care3. core

core

dogwood4. DANSER

DANGER

EPS5. EPS

IBM

foundry6. foundry

family

gray sand7. green sand

green sand

heat8. heat

he

wine9. iron

iron

July10. July

June

406

K -Mart11. Kentucky Fried Chicken

Kentucky Fried Chicken

time12. lost foam

lost foam

McDonald's13. McDonald's

McDougall's

No Smoking Area14. No Smoking Area

No Parking Zone

OK15. OK

oh

pay check16. pattern

pattern

quality control17. quality control

high quality

Robinson family18. Robinson -Bodine

Robinson Foundry

STOP19. STOP

Start

taxis20. taxes

taxes

D Street21. U Street

U Street

V-8 engine22. V-8 engine

V-6 engine

Wal-Mart23. Wal-Mart

wishing well

x-ray24. x -ray

x-rays

you25. you

yes

ZOO

26. zero .

zero

42 SI 8

5a. Underlining

I live in Alex City.I work on the BP Machine.Run a core on this job.

The sign says 'Danger'.I work in the EPS Department.I work in a foundry.

I work on the Green Sand line.We heat the iron.We heat the iron.

We eat fried chicken on July 4th.We eat Kentucky Fried Chicken on July 4th.I work on the lost foam process.

We eat at McDonald's.McDonald's has a No Smoking Area.It's OK to smoke in the parking lot.

The pattern number is 346036.I work in the Quality Control Department.I work at Robinson Foundry.

The sign says 'STOP'.You can't stop taxes.The sign says 'U Street'.

That Ford has a V-8 engine.That Ford is parked outside Wal-Mart.Get an x-ray at the Alex City Hospital.

You can't stop taxes.Five, four, three, two one, zero.

4

5b. Underlining

We eat at McDonald's.We heat the iron.I work on the BP Machine.

The sign says 'Danger'.I live in Alex City.I work in a foundry.

The pattern number is 346036.We heat the iron.That Ford is parked outside Wal-Mart.

I work in the Quality Control Department.I work in the EPS Department.We eat fried chicken on July 4th.

You 'can't stop taxes.Five, four, three, two one, zero.I work on the Green Sand line.

McDonald's has a No Smoking Area.It's OK to smoke in the parking lot.

That Ford has a V-8 engine.

I work'at Robinson Foundry.I work on 'the lost foam process.The sign says 'STOP'.

The sign says 'U Street'.You can't stop taxes.Get an x-ray at the Alex City Hospital.

We eat Kentucky Fried Chicken on July 4th.Run a core on this job.

490

6a. Fill-in-the-blank

I live inI work on theRun a on this job.

The sign saysI work in the Department.I work in a

I work on the line.We the iron.We heat the

We eat fried chicken on 4th.

We eat on July 4th.I work on the process.

We eat atMcDonald's has aIt's to smoke in the parking lot.

The number is 346036.I work in the Department.I work at

The sign saysYou can't stopThe sign says

That Ford has aThat Ford is parked outsideGet an at the Alex City Hospital.

can't stop taxes.Five, four, three, two one,

6b. Pill-in-the-blank

We heat theI live inI work in the Department.

We eat atThe sign saysI work in a

You can't stopWe the iron.It's to smoke in the parking lot.

I work on theWe eat fried chicken on 4th.I work in the Department.

I work on the process.That Ford is parked outsideGet an at the Alex City Hospital.

McDonald's has aRun a on this job.The number is 346036.

el- I work at .

..,_ I work on the line.The sign says

The sign saysWe eat on July 4th.That Ford has a

can't stop taxes.Five, four, three, two one,

7a. Narrative

1.

I live in Alex City and work at a foundry. Some of the departments

at Robinson Foundry are the Green Sand line, EPS, and Quality

Control. A sign says 'DANGER" near where we heat the iron.

The first job for the BP Machine today had a core in the mold.

That job's pattern number was 346036.

2.

Five, four, three, two, one, zero.

3.

I live in Alex City on U Street. I drive a V-8 Ford. I work at

Wal-Mart and eat at McDonald's and Kentucky Fried Chicken. Both

places are OK to eat at.

I can read signs. The sign at the end of the street says 'STOP'.

Signs at the Alex City hospital say 'No Smoking Area', and 'X-ray'

machine..

4.

The year has these months in it: January, February, March, April,

May, June, July, August, September, October, November, December. In

January I file my taxes with the IRS. Then I have zero dollars

left.

7.b Narrative fill-in-the-blank

1.

I live in City anddepartments at RobinsonQuality Control. A sign says

work at a foundry. Some of theare the Green line, EPS, and

near where we heat the iron.

The first job for the BP

job's number was 346036.

2.

today had a core in the mold. That

Five, four, three, two, one,

3.

I live in Alex City on U . I drive a Ford. I work at

Wal- and eat at McDonald's and Fried Chicken. Both

places are to eat at.

I can signs. The at the end of the street says 'STOP'.

Signs at the Alex hospital say 'No Area', and 'X-ray'

machine.

4.

The year has these months in it: January, February, , April,

May, June, , August, September, October, November, December.

In January I file my with the IRS. Then I have dollars

left.

7c. Narrative Multiple Choice

I

1. I live

a.b.

in Alex City.in Robinson Foundry.

2. I work

a.b.

3. EPS

a.b.

at Alex City Hospital.at Robinson Foundry.

is a department.is where we heat the iron.

4. The job's pattern number

a.b.

II

was 346222.was 346036

1. Five,' four

a. threeb. zero

2. one + three =

a. fiveb. four

III

1. I live

a.b.

in Alex City.in the machine.

2. I eat at

a. Wal-Martb. McDonald's

3. The sign at U Street says

a.b.

'STOP''x-ray machine'

4. The sign at Alex City Hospital says

a.b.

IV

'DANGER''x-ray machine'

1. January, February

a. Julyb. March

2. I file my taxes with

_a. the IBM.b. the IRS.

3. .October, November

a. Juneb. December

r.)