communicate with the mixer via bluetooth. “When the mixer has dispensed a certain amount of sand, it will automatically stop, and the control system will send a signal to the table to vibrate at this intensity for this long, shut the table off, then restart the mixer.” Two cranes take molds from
either line, roll them over and set them onto one of the new con- veyors, which move them down to the coating area. Hydraulic arms pin the mold to the flow coating table, which lifts the mold for coating. Te operator blows any loose sand from the mold and then applies the alcohol-based wash. Te runoff is reused, and Sivyer is working with its coating supplier to improve efficiency, as the wash evaporates quickly in the pan. Te company is considering the switch to a water-based wash, which will require dryers instead of burnoff with a torch, so space has been left on the conveyor line for that equipment. Other adjustments the
operators have made on the fly include the use of wood spacers to ensure the conveyor deck isn’t damaged, particu- larly by large molds. With the new conveyor
lines, the cranes are zoned to stay in the same area, which improves workflow, speed and safety. Other lean tech- niques are as simple as using free space in a mold to do ghost castings of necessary items such as clamps. Mohs noted the reduction
in workers needed to perform each task, thanks to the new equipment. “It’s a win-win, because we’re adding capacity,” he said. “Everybody has a job. Tey all know where they’re moving. We can now do more with fewer people than we ever could before.” On the day of our visit,
Sivyer Steel pours approximately 11,000 tons per year and is aiming to double that figure as it works toward completing its latest expansion.
CASTING STEEL FOR MORE THAN A CENTURY Sivyer Steel, Bettendorf, Iowa
Sivyer Steel, Bettendorf, Iowa, was founded in Milwaukee in 1909. Its first customers were farm equipment mak- ers, and mining and crane equipment components were soon added. Sivyer Steel developed a new molding pro- cess in 1916, enabling the conversion of truck spring seats and caps from iron to steel. The company purchased a Chicago steel casting facility in 1925 and, 10 years later, became the first metalcasting company in the U.S. to
Metals Cast: Carbon, low alloy, austenitic manganese and stainless steels, high chrome iron
Casting Processes: Nobake
Size: 30 acres, 325,000 sq. ft. owned, 100,000 sq. ft. leased
Employees: 350
Primary Markets Served: Mining, military, crane/construction, railroad, recycling, energy
pour armor steel castings for the National Defense Department. Sivyer is famous for producing the steel bollards protecting sites in Washington, DC, from vehicular attack.
Following the move from Chicago to Bettendorf in 1961 (the Milwaukee facility remained in operation until 1971), Sivyer produced cast armor for tanks serving in the Korean War, which brought modernized equipment to the facility. Sivyer expanded its customer base in 1984 and added a machine shop in 1987. It also houses Riverside Products, a subsidiary company that produces alloy and manganese wear parts and rotor assemblies for the automobile shredding industry.
Changes in ownership brought about a focus on continuous improvement that has paid dividends. It became a certified sup- plier for Caterpillar Inc., saw a zero percent reject rate in 1991 and gained recognition from other customers. Sivyer established
Sivyer was pouring CA6NM stainless steel. Te lead opera- tor tapped the heat, tested and
a global presence, with sales offices in Japan, Canada, England, Germany, The Netherlands and Korea. In 1993, it invested in the MAGMAsoft casting simulation system. The company became ISO-9002 certified in 1994 and created an alloy development program for niche markets, imple- mented advanced heat treatment and began the beneficial reuse of spent sand and other materials.
The recession at the turn of the century resulted in Sivyer’s purchase by Facilitator Capital Fund, a Wisconsin-based small business investment corporation. At the time, Sivyer’s business model emphasized smaller, commodity-based wear parts for the construction and recycling industries. Arthur Gibeaut took the reins as president and CEO in 2002 and led the company to a 63% increase in sales by 2004. An ongoing focus on develop- ing the sales force brought the company to its current phase of sustained growth. Sivyer had a record year in 2008, which put it in good stead as the economy took a turn for the worse. During this time, it outsourced its small casting production to Indonesia and China.
Sivyer is approaching the $100 million/year mark as it contin- ues a massive facility upgrade that is expected to be complete within the next few years, with more changes to come.
March 2013 MODERN CASTING | 31
Ford Photography—
JoshuaFord.com
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