Face CASE22 Face

Casting Module 2, Engine Plant, Suzuka Factory, Honda Motor Co., Ltd.

Cylinder sleeve production at Suzuka Factory before 2001

Cylinder sleeve

What is casting anyway?
  Metal casting is a production process in which metal (steel, aluminum, copper, brass, etc.) is melted at a high temperature, poured into a mold, and then cooled and hardened. There are various types of casting methods depending on the mold material, such as sand mold casting, plaster mold casting, and metal (permanent) mold casting. The cast object is called a casting.
Sand casting is one of the oldest casting methods.
 Of the many types of casting, sand mold casting is one of the most ancient. It is said that sand casting began in Mesopotamia around 4,000 to 3,500 B.C.E. In Japan, sand casting may have been used to make weapons and other tools as far back as 2,000 years ago. Incidentally, the giant Buddha statue in Nara, Japan, was made using sand casting. Because sand casting offers numerous advantages such as low mold costs, quick prototyping, and the ability to make complex shapes, many metal products and parts are still produced using this method even today.
Cylinder sleeve production using sand casting
 Sand casting posed a major barrier to improvement of working conditions at Suzuka Factory. All steps in the sand casting process required associates to wear a face mask, ear plugs, and protective eyewear and to work in temperatures ranging from 35 to 40ºC (95 to 104ºF). Moreover, roughly 50% of the industrial waste generated by Suzuka Factory at that time came from the sand casting line (most as spent sand), and reduction of this waste was a high priority. United under the campaign slogan, "No more sand," associates looked into various alternatives, including metal mold casting, but eventually decided to introduce the Spincast method, a centrifugal casting method adapted and perfected by original Honda technology.

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