Navistar’s Melrose Park, Ill., plant produces service engines for military vehicles.
We’ll make some of those strategic decisions because it’s about total cost, not just piece cost.” According to Kashanipour, Navi-
star finds the greatest value in the retention of knowledge at the Waukesha casting facility, which can be reaped through the manu- facture of complex castings on-site or for troubleshooting following a failed casting attempt at another facility. For example, a pump cover produced at a supplier in India was failing at a rate of 50%. The design for the casting featured tolerances only machining could achieve, but due to a lack of communication, the error was not caught. Navistar has decided to re-source the pump cover for casting at the Waukesha plant and finish-machining at an in-house machining facility. “A process that would take 22
weeks to design and validate, we will be able to re-source within weeks [because it is done in-house],” Kashanipour said. “The way we keep people here knowledgeable about the process is to keep Waukesha. We believe that is a huge competitive advantage to us.”
METAL 28 MetAl CAsting Design AnD PurChAsing July/August 2010
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