The metalcaster and design team can use process modeling software to determine problem areas in a metal casting and produce the optimal part configuration.


casting supplier to one that is world-class. So what makes a supplier world-class? Consistent on-time delivery of high integrity components at a fair price should be a given. It is the attributes beyond those that truly define a metalcaster. Accurate, timely communication between


the OEM and the metal casting source is criti- cal in maintaining a strong relationship. Working together as a team to provide weekly (or even daily) updates on production efforts will eliminate the mystery that can sometimes plague the relationship. Te OEM needs to know “what, where and how long” to keep its manufacturing operations flow- ing smoothly. Invalid information will only create frustration and delays and hamper the efforts of the purchasing team. Without this vital line of com- munication, the casting facility is only a vendor and not a true world-class supplier of cast components. One key facet to any world-class operation is


the knowledge base and innovative thinking of the engineering department. Strong engineering teams possess the knowledge and guidance to make new parts right the first time and improve existing products and processes. Te use and knowledge of modern technology, such as solidification modeling, will allow the engineer- ing department to prove out methods prior to mold development. Another key asset is the supplier’s ability to


work alongside the OEM to develop new cast products from fabrications or improve existing manufactured products by offering a castable option. Not all new casting orders come right from the customer or are transferred from an- other source. Some are developed by world-class metalcasting engineers working with the OEM. A metalcaster without a dynamic and involved engineering department rarely will be part of new product development or able to improve the components it already produces for you. Product knowledge and application play a key role in truly understanding the needs of the customer.


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Metal casting suppliers that make significant efforts to understand the final use of the products they produce will be able to add value to the relationship. Tese sup- pliers can offer suggestions for product improvements, cost reductions and applications where a casting will be best suited. Relationships that mature to this level are a true asset for the OEM and help assure a long standing association between the two companies. In order for any metalcasting operation to


achieve world-class status, it must continually improve its quality systems. Accurate, detailed and constantly updated work and process instructions are essential to any operation. Te word-class quality department takes true product quality one step further. Tese operations are continually veri- fying processes prior to any problems. Tey also have a strong knowledge of their customer’s speci- fications and how they apply in each situation that may arise. Without this level of commitment from the quality department, your product’s quality and delivery will be in question. World-class metalcasting companies also must


develop quality new employees. Metalcasting is an art that relies on the knowledge and experience of those involved. Without the development of new employees, the metalcasting facility’s world-class status will be short-lived. Metalcasting facilities must take advantage of their experienced work- force to educate the next generation. Furthermore, world-class operations must promote safety among their employees and visiting customers.


Continuous Improvement Most procurers of engineered cast components


have run into delivery and quality issues. While a majority of these are quickly corrected, some sup- pliers consistently fail to meet expectations. What do you do to restore the relationship and help your suppliers find their way back on track? Often, metal casting suppliers take on work that does not fit their capabilities or agree to ag- gressive delivery or quality requirements they are


METAL CASTING DESIGN & PURCHASING / 2012-13 Metalcaster Prospectus


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