capacity is not allowed to exceed more than 30%, so the company has the ability to adjust its customer, product and order structure. For the development of new customers, the group received a new national civilian nuclear safety equip- ment manufacturing license in 2008. When demand in the market increases, some investment casting enterprises do not expand production capacity on a large scale and instead focus on product processing, outsourcing some orders to other companies. When orders are insufficient, they pull their orders back from these companies, so their production is minimally affected. Usually, investment casting facility production is order-
based. So, the adjustment of product structure is passive, which affects market expansion. However, Dongfeng Investment Casting Co. Ltd. actively expands its market by optimizing product structure, such as reducing the weight of castings, simplifying casting structure and integrating individual parts into a single investment casting. To achieve the conversion, lean design is used to reduce large flat sur- faces and long, small holes, modify walls with large varia- tions with reinforcement ribs, reduce machining allowance, and decrease weight. Computer aided engineering and test benchmarks verify the modified design for the customer. Meanwhile, light-weighting of the new parts reduces cost, satisfying customers about the new design. Tese kinds of efforts have contributed to the lightening of vehicles, and the application of investment castings has expanded sig- nificantly. For example, investment castings used in trucks have increased from 40 kg (88 lbs.) per car to 300-400 kg (661-881 lbs.) per car, a tenfold increase. At the same time, the yield has increased to 65% through the optimization of part design.
Enforcement of Management
Together with technology, management is one of the two wheels that drive growth, improvement and development. During the global economic crisis, some enterprises fell to mismanagement, falling benefits and capital shortage. Internal management can be strengthened by updating the manage- ment concept, innovating the management mechanism and standardizing management behavior. Te idea is to produce more products while using less resources to realize the highest output, efficiency and benefits at the lowest cost. Strengthen- ing management is the most useful tool to convert crisis to opportunity. Some companies adopt
modern management sys- tems, such as the ISO9000 quality management system
Figure 2. Europe, North American and Chine produce different types of investment castings.
响了新市场的开拓。东风精铸公司为更好的开拓市场， 介入产品结构优化，他们充分利用熔模铸造可生产精密 复杂件的优点，对产品进行“减重、简化、替代”。 即对能熔模铸造生产的原有砂铸件、锻件、冲压件、 焊接件、机加工件、装配件，进行精益设计：千方百计 减少大平面、长孔、深孔，使壁厚均匀化，使用筋等、 减少加工、减重。并应用有限元技术、CAE技术、台架 试验等对精益设计的产品进行性能验证，从而使产品 在保质前提下，轻量化和降低成本，让客户放心和满 意，将产品交企业生产。多年来的实践使他们在汽车轻 量化作出了贡献、扩大了精铸应用范围，增加了市场 份额。如载重汽车原每辆车精铸件仅40kg，现提高到 300～400kg，为原有的10倍。同时由于介入产品结构 设计，优化了精铸件结构、生产时工艺出品率也大为提 高，现企业平均工艺出品率达65％。这种新的经营开发 模式得到行业中其他企业的关注。
加强企业管理
管理是企业永恒的主题。可以形象地说：技术和管 理是企业前进、提高和发展的两个轮子。在全球经济危 机影响的过程中，部分企业生产经营困难，经济效益 下滑，资金链紧张。要渡过难关，最现实、最有效、最 有潜力和主动权的是强化内部管理，更新管理理念，创 新管理体制、规范管理行为。争取用最少资源生产出最 多产品，用最高效率获得最大效益，用最低成本取得最 高的利润。因此，加强企业管理是现实有效的“化危为 机”的突破口。
行业中部分企业向现代管理发展，通过ISO9000质量 管理体系认证、ISOTS16949汽车行业质量管理体系及 其他有关的认证，应用计算机管理信息系统对营销、生 产、库存、人事、工资、成本等进行完整快速的管理， 有些企业在推行“精益生 产”等取得良好的效果。 但一些企业的管理水平仍 较差，急需赶上。
重环保，抓节能
精铸生产过程中的排 放物有废蜡模清洗剂、粉 尘、废脱蜡水、废蜡、焙
图2 2007年欧美中熔模精密 铸造的产品分类. (中国熔模精 密铸造未统计水玻璃型壳精 铸件）.
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION Summer 2011
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