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“But a lot of times what we have found is that you can get a rough machined casting overseas for the price of a domestic casting without any machining. Domestic casting fa- cilities have first right to a part, but if it doesn’t make [financial] sense, we do go overseas.”


Turning a Profit


For most of its more than 100-year existence, Dayton Foundry was oper- ated as a cost center, generating com- ponents for end use in pump and valve assemblies without the expectation of creating revenue. While the plant did not produce a


profit for its parent company, it was kept running for strategic reasons, including the development of highly corrosion resistant alloys. In 2002, Flowserve decided to turn


Flowserve’s Dayton Foundry cast this titanium impeller part.


aids in the development of new cast- ing sources and at times takes part in determining total landed cost of a part, which includes the cost of inventory, tariffs and lead times. Flowserve puts new casting sources through an ex-


tensive trial process to make sure the predicted cost savings are achievable. “There’s a dynamic when deciding


what’s going to be sourced to a least cost country, because not everything makes sense overseas,” Porreca said.


the facility into a profit center with the purpose of generating revenue. Dayton Foundry worked to reduce its operat- ing costs and tried to backfill its open capacity with commercial casting work. But the attempts failed to make the business unit immediately profitable. In 2006, Flowserve brought in a new management team, including Porreca and Carano, who is the company’s first


In some instances, vertical gating fits the bill for nobake castings at Flowserve.


28


Dayton Foundry’s centrifugal process is used to produce pipes for the plumbing industry.


MODERN CASTING / June 2010


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