Criticality-Driven Reliability Enhancement of Pneumatic Sand Molding Cells in Foundry Applications via FMECA

In modern foundry operations, the reliability and operational continuity of sand molding systems are pivotal to maintaining productivity, safety, and competitive advantage.In this study, Failure Mode, Effects, and Criticality Analysis (FMECA) has been employed to systematically evaluate and optimize the performance of a pneumatic molding cell utilized in the production of sand molds.Particular focus has been directed toward the pusher subsystem, which is frequently subjected to high mechanical loads and cyclic stress, rendering it susceptible to recurrent failures that compromise both uptime and process efficiency.Potential failure modes were exhaustively identified, categorized, and prioritized based on their severity, occurrence, and detectability.Critical components, including servo motors, pneumatic actuators, and gearbox assemblies, were found to pose substantial risk to system reliability due to wear-induced degradation, misalignment, and lubrication failure.For each high-priority failure mode, targeted mitigation strategies were proposed, encompassing enhanced condition monitoring, retrofitting of wear-resistant materials, and redesign of high-stress interfaces.Furthermore, failure detection mechanisms were improved through the integration of predictive maintenance protocols and sensorbased diagnostics.Implementation of these recommendations has resulted in measurable reductions in unplanned downtime, repair frequency, and maintenance overhead.This investigation demonstrates that FMECA, though underutilized in conventional foundry environments, offers a structured, data-driven methodology for uncovering latent failure risks and implementing preventive measures in complex industrial systems.By embedding FMECA within routine maintenance frameworks, a substantial improvement in operational resilience and equipment lifespan can be achieved.The findings support the strategic integration of reliability engineering methodologies into sand molding operations, contributing not only to cost efficiency but also to the broader adoption of systematic risk management practices in process-driven manufacturing sectors.