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Creating solutions to keep your casting processes productive and profitable.
Engineering Consulting FOUNDRY ENGINEERING CONSULTING MANAGEMENT CONSULTING
CASTING DESIGN CONSULTING PROGRAM MANAGEMENT CONSULTING

Foundry Engineering Consulting

Foundries are often in need of expertise they don’t have on their engineering staff, either because they are understaffed or inexperienced. Understanding how to determine root causes to quality problems is extremely important when trying to solve those problems. Projects which we have undertaken include solving ceramic core problems, improving wax pattern injection processes, improving tooling design, improving productivity and reducing or eliminating causes of casting scrap.

Our approach is to perform an initial assessment, which entails visiting the client’s facility. During the assessment,

we meet with key personnel to understand what areas they feel they need the most help in. We spend time in the plant, walking the process to observe the current conditions that exist with an eye for where opportunities for improvement lie. This provides enough insight to define the project.

Examples of having successfully identified and corrected root causes for scrap:

• Improved dimensional casting yield from 50% to 95%, enabling the client to deliver on time within weeks after employing our solution.

• Increased casting yield on a high-volume part from 20% to 90% by virtually eliminating the source for foreign material inclusions.

• Identified the root cause for casting cracks.

• Increased the yield on extremely complex cored wax patterns from 30% to 81%.

• Improved ceramic core dimensional capability by 100%.

• Eliminated wax pattern blisters on a high volume part.


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Foundry Engineering Consulting | Management Consulting | Casting Design Consutling | Project Management