Pure Power Metalcastings Group Waukesha, Wis.


Affi liation: Part of Pure Power Technolo- gies, a Navistar Inc. company.


Metals Cast: Ductile, austempered ductile and compacted graphite iron.


Molding Process: Green sand.


Markets Served: Heavy truck and engine, mili- tary, agriculture, construction and hydraulics.


Size: 240,000 sq. ft. Employees: 181.


“We still service Navistar and will continue to, but we could get 25,000 tons of Navistar business and still have 25,000 tons available for other customers.” —Rick Bacon, Navistar Inc.


“Without the bedplates, we couldn’t


have survived without more volume replacing it,” said Rick Bacon, director of metalcasting operations. To combat the lost volume, last


summer the metalcasting facility opted to shift its focus from being captive to bringing in new customers. The plant had been making parts for other OEMs, but that consisted of a small portion of its overall business. Now, its goal is to produce 50% Navistar products and 50% other OEM products. “At any point, volumes in Navistar


products can go down, and we wanted to get into other segments to offset the downturns of the heavy truck industry,” Bacon said. “We still service Navistar and will continue to, but we could get 25,000 tons of Navistar business and still have 25,000 tons available for other customers.” Navistar set a goal for the metalcast-


ing facility to reach $200 million in sales by 2015 and be in the black by 2011. According to Bacon, to break even, the plant has to pour 1,600 tons a month. This summer, the facility cast about 1,200 tons a month, while at other times during the year it has poured as many as 2,400 tons in a month. “We are defi nitely in the ballpark to


reach the company’s goal,” Bacon said. The casting facility also targeted


5,000 tons of new OEM parts and 5,000 tons of new Navistar jobs by October. New orders began to materialize in the fall of 2009 and have come from the


MODERN CASTING / October 2010


Pure Power-Waukesha will be casting key components of the emissions-reducing EGR valve in Navistar’s MaxxForce engines.


17


military, agriculture, hydraulic motors and construction markets. As of August, the facility had gained 2,700 tons of new Navistar parts and 4,400 tons of new OEM parts. “On the OEM side, I’m confi dent


we’ll achieve our goal this year,” Bacon said.


On the Job Turning Navistar-Waukesha into a


job shop didn’t happen with a single


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