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sales person dedicated solely to acquiring com- mercial casting work. At around the same time, the company began consoli- dating its casting opera- tions to operate as a singe metalcasting facility. “The facilities used to


be run as four or five independent foundries, and they were scheduled independently,” said Por- reca, who worked for a commercial metalcaster prior to joining Flowserve in 2006. “In the transition from captive to entering the commercial market, we had to become a little more flexible and leaner. We had to become more nimble in the marketplace, both cost-wise and lead time-wise.” Porreca credits the facility’s union


said. “The only way to prove that to an outside customer is to actually do what we say we are going to do when given the opportunity.” Flowserve feels its experi-


ence in corrosion-resistant materials, such as nickel- base superalloys, and super duplex stainless steels, can translate into producing parts for other markets, such as power generation and nuclear energy.


Making an Investment


Flowserve offers castings up to 22,000 lbs. If it is too big to cast at Dayton Foundry, the company sources to Flowserve casting sup- plier Canada Alloy Castings.


not a captive foundry, but a creative foundry,” Carano said. Carano’s first focus has been cus-


for having the flexibility to accomodate changes to job responsibilitie and duties that were necessary to consolidate the casting facilities. “With the assistance of the local


union, production efficiencies have increased and labor costs and overall production costs have come down sig- nificantly,” Porreca said. “Without the backing of Flowserve and the efforts of a committed and talented work- force, we would not have survived.” Now, two supervisors oversee all


the molding and pouring processes and coordinate the schedules for all areas off of one master schedule. Since the change, the casting


facility has picked up speed in non- captive casting orders, although cur- rently 95% of the castings made at the plant are still captive (the goal is 75% captive and 25% jobbing). In the last nine months, Dayton Foundry has begun breaking even. Carano cites Dayton Foundry’s


place as part of Flowserve Corp. as an advantage when selling capacity on the open market. The casting facility has had to compete on cost and delivery for orders from the dozens of customers within the Flowserve organization, much as a jobbing facility does. Carano makes sales calls, fills RFQs and gives feedback on quotes for his Flowserve customers. “I like to tell people we are


MODERN CASTING / June 2010


tomers within the industry it knows best—pumps and valves. Some custom- ers are direct competitors to Flowserve, which Porreca admits can be a hurdle for potential new prospects. Dayton Foundry invites customers to visit the casting facility and perform their own audits. “We have to be able to manage the capacity so that both are serviced,” he


Beyond its tried and true capabilities in high-alloy steel casting production, Dayton Foundry added rapid prototyping (RP) for


speed to market and to service the aftermarket business, mostly in repair parts four years ago. The facility can produce RP parts in any material it pours in its steel casting facility. “Another advantage of the RP pro-


cess is that we can use it in the R&D stages of components,” Porreca said. “A part can be designed, cast as a prototype and tested. Changes to the design can be made, then another part produced and tested. Once the final design is accepted, the permanent tooling can be built.” According to Carano, the RP


services offer another entry point for potential customers to come to Dayton Foundry. The ultimate goal is that some parts that start as R&D projects eventually become full pro- duction orders at the facility. Dayton Foundry’s investment


in RP came around the same time as Flowserve invested in six new melting furnaces and six new heat treat furnaces—indications that the pump and valve company has further plans for its metalcasting facility. The fact that Flowserve kept its casting facility in opera- tion for so many years while it was unprofitable points to at least one advantage the captive shop has over other job shops. “Flowserve’s financial strength


In 2006, Dayton Foundry began consolidating the melt centers of its five casting processes.


and the strategic advantages the foundries bring to the table have allowed the facilities to continue to operate, where many private foundries would not be able to,” Porreca said.


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