Industries · Foundry
A foundry’s losses are spread across the whole line — energy drift at the furnace, sand defects at moulding, misruns at pouring, rework at fettling. Each one is small enough to average away in a monthly report, and each one has a reason the operator knows and the ERP never captured. Munshi joins the furnace and line readings to the operator’s log, stage by stage.
Your ERP logs the heat, the mould count, the pieces dispatched.
It won't tell you the furnace held on a crane, the sand ran hot, or the casting came back to fettling twice.
Why the gap existsThe line
Follow the metal. Each stage below is where a particular loss hides — and where Munshi surfaces it with the cause joined from the floor.
For scale on just the first stage: a US Department of Energy study put best-practice batch induction melting at 530 kWh per ton of melt.1 That is a 2004 figure and an order-of-magnitude anchor, not a grade for your plant — but energy is only one stage of several, and the same “correct number, missing reason” gap runs through all of them.
Start where you already suspect a loss.
Melting, moulding, fettling — pick the stage that bothers you and see it against a month you already know.