AbstractTwo previous studies of the application of the techniques of information technology and statistics to the relatively low‐level records of a semi‐automated iron foundry have been made. Each has contributed to better knowledge and understanding of variables of the casting process, in the course of solving a specific problem. Encouraged by the enthusiasm for and quality of record keeping evident during the studies, it was decided to use the same investigative approach to make a deliberate search for any opportunity that might exist for improving the quality and/or productivity of green sand moulding.Data collected over a period of ten weeks were analysed under four broad headings: products, input materials, process operations and control of process variables. A comparison of production figures from the start and finish of the datum period revealed a reduction in the mould rejection rate of 40 per cent with reductions in inputs of new sand and bentonite of 42 and 12 per cent, respectively. The seemingly onerous task of good process record keeping had proved to present an opportunity in disgu