2012-13 METALCASTER PROSPECTUS ThyssenKrupp Waupaca, Inc. Gary Gigante President, CEO, COO Mission Statement


ThyssenKrupp Waupaca produces iron castings, focusing on trans- portation, construction, agriculture and industrial markets worldwide.


We embrace lean manufacturing techniques in all our facilities, and manage other value added services for our customers. Our custom- ers’ expectations are met through innovative technology, continuous improvement culture, and the ef- forts of our dedicated, motivated, highly-trained workforce.


We maintain strong social and envi- ronmental commitments to our em- ployees and communities, including: improvements sustained through


green initiatives, a well maintained and safe environment and the en- couragement of employee’s personal growth through advancement and continuing education.


Metals


Gray iron, Ductile Iron,


Austempered Ductile Iron, Compacted Graphite Iron


Processes Vertical green sand molding


ThyssenKrupp Waupaca Plant 1 406 N. Division St., P.O. Box 249, Waupaca, WI 54981


ThyssenKrupp Waupaca Plant 2/3, Waupaca, Wis.


1955 Brunner Dr., P.O. Box 249, Waupaca, WI 54981


ThyssenKrupp Waupaca Plant 4, Marinette, Wis. 805 Ogden Ave., Marinette, WI 54143


ThyssenKrupp Waupaca Plant 5 9856 State Highway 66, P.O. Box 189, Tell City, IN 47586


ThyssenKrupp Waupaca Plant 6 134 Waupaca Dr., P.O. Box 510, Etowah, TN 37331


www.thyssenkruppwaupaca.com METAL CASTING DESIGN & PURCHASING / 2012-13 Metalcaster Prospectus 25


ThyssenKrupp Waupaca has a reputation as solid as the castings we create. Quality is our reputation. It’s our heritage. And it will be our legacy. Quality is what dif- ferentiates ThyssenKrupp Waupaca from the rest. We hold ourselves to a higher standard. And we stand by it, producing the most con- sistent, high-quality iron castings in the world. With headquarters and three plants in


Waupaca, Wis., as well as plants in Marinette, Wis., Tell City, Ind., and Etowah, Tenn., ThyssenKrupp Waupaca operates six found- ries and employs more than 3,700 people. ThyssenKrupp Waupaca produces gray iron, ductile iron, austempered ductile iron, and compacted graphite iron castings, melting more than 9,500 tons a day. Castings up to 350 pounds or 160 kilograms are produced using one of our 33 vertically parted high pressure molding machines by a workforce that puts generations of iron casting expertise to work for our customers every day. ThyssenKrupp Waupaca consistently pro- duces the most durable, reliable, and innova- tive castings on the market.


Our Process Since establishment in 1955, ThyssenKrupp


Waupaca has patented many improvements to the industry’s vertical green sand molding with regard to safety, quality, productivity, and reliability. Our innovative thinking is a large part of how we’ve led the industry in delivering consistent high-quality castings. ThyssenKrupp Waupaca’s design engineer- ing, high volume melting capabilities, custom and proprietary vertical green sand molding equipment, and automated fi nishing systems minimize post-process machining require- ments and maintains controlled chemistry


for consistent machining—all resulting in best-in-class iron castings.


Our Technology ThyssenKrupp Waupaca’s top leaders, manufacturing teams, engineers, and metal- lurgists are involved in controlling process consistency and continuously improving our technology. Our metallurgists and engineers design proprietary processes and customized equipment to monitor iron temperature, ad- ditives, casting materials and processes to a hyper-detailed level.


And, our engineering support teams help customers to reduce their total manufacturing costs through innovative casting and core passage designs, waste reduction, and mass reduction improving casting consistency and quality. And, in some casting applications we even help reduce the need for multiple cast, fabricated or welded parts. For customers, all of this ensures castings are consistently durable and reliable.


Markets Served ThyssenKrupp Waupaca produces castings for global market segments including the light truck and passenger car, commercial vehicle, agriculture, construction, material handling and other industrial sectors. Our castings are engineered with the latest technology, meticulously melted, carefully produced on our customer-engineered mold- ing machines and perfected by our automated fi nishing systems. Together, this provides long-term value to our customers with the most consistent, high-quality iron castings, providing cost savings and dependability. For more information, please visit www.thyssenkruppwaupaca.com.


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36