2013 Metalcaster ProsPectus
Conducting a Productive Metalcasting Supplier Visit Any visit to a metalcasting facility can be worthwhile, but the first visit can be either the green light for a long customer- supplier relationship or a road sign telling you you’re on a dead-end street. Although every metalcasting facility will welcome current and potential cus- tomers differently, a design review is a critical part of the visit because it gives you the chance to discuss aspects of the component’s design, as well as base metal price and weight differential, face to face. You can discuss problems encountered with an existing part, or if it is a new part, involve the metalcaster’s design team at this stage to aid in its manufacturability. During the introductory meeting, the casting supplier likely will give an overview of the company. Like many manufacturing sectors, the metalcasting industry is under pressure from domestic and foreign competition. An unexpected plant closure could affect your time to market. A good gauge of the health of a company is its recapitalization plans. What have they invested in lately, and what are they going to invest in tomor- row? The new equipment may not affect the production of your part, but invest- ment commitment is a sign that the firm will be around to be your supplier today and down the road.
SHANNON WETZEL, SENIOR EDITOR
metalcaster controls its process. Metal- casting’s main concerns are the metal and the mold, and these parameters should be tested on a regular basis. For instance, controlling the sand in a sand casting facility is important in molding efficiency. Ask the employees in the testing area what they are testing for and the frequency of the tests. You won’t have to be an expert on sand to see their competency level. How well does the employee understand what the tests are telling him or her?
Finally, housekeeping on the shop floor should be evident. Because of the nature of the process, dirt and grime will be present, but major things to look for are clear walkways, neat workspaces and a generally trash-free environment. Don’t neglect the chance to meet with the employee population handling your component. A strong engineering staff will help you save money and improve part quality, but the workers on the molding line, in the melting department and at the grinding wheel are the ones who will carry out the plan.
It may also be worthwhile to spend some time asking about how the firm finds its employees and what training programs are in place. An engaged, satisfied production
But a metalcasting facility doesn’t necessarily need the shiniest new equipment to produce quality cast- ings. The company’s maintenance plan is a clue to its longevity. The organization and operation of the plant is just as important as the equipment in a high class metalcasting facility. Your first visit will be a largely educational one, but even if you are un- familiar with the casting process, you can be on the lookout for telling signs, such as people working unconnected to other departments or large piles of material. Most containers of in-process cast- ings have tags or production sheets with them. Check the dates to see how fresh the castings are. Are they getting addressed that day? While you are walking the shop floor,
look around for castings that are similar to your part and ask questions about them. You’ll also want to see how the
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workforce translates into an efficient manufacturing process and higher qual- ity castings. Simple things like a bul- letin board with fresh postings, a clean breakroom and even a parking lot full of well-maintained cars can be clues to the type of workforce employed.
Simple Signs of a Quality Supplier
These facility aspects are indicators
of how well organized and committed to quality a casting supplier is. Keep an eye out for these tell tale signs on your next metalcasting facility tour.
Green Flags
• Strong sales figures • Busy shop floor with plenty of work in place • Open plant tour with questions answered easily and comfortably • Clear walkways, tidy workplaces • Safety equipment used • Progressive capital investment plan
Red Flags
• Poor housekeeping, evident garbage in work areas, no clear pathways • Prohibit you from viewing certain areas of plant (unless for safety or proprietary reasons) • Unprepared for visit or employees unaware of a meeting with the customer • Evident lack of safety procedures
The Lead Time Riddle As a casting customer, one of the first questions you’ll have is, what’s the lead time?
In the last decade, metalcasters have taken advantage of new equipment and lean manufacturing methods to shrink their lead times to deliver parts faster. In general, a good metalcasting facility will have lead times that are short enough for customers in its key markets to react quickly while still delivering at an economical price. But calculating lead times is a complicated process that differs from metalcaster to metalcaster. To add to the confusion, lead times for the same part at similar facilities can vary greatly. To get to the heart of the matter, ask for specifics on what the lead time is based and what it includes. Typically it includes tooling design, procurement of material to make the tool, cutting the tool, sampling, gating design, X-ray validation and possibly preproduction machining. But it’s a good idea to ask the casting facility, to be sure. And if you have specific scheduling requirements, it’s important to mention them up front.
METAL CASTING DESIGN & PURCHASING / 2013 Metalcaster Prospectus
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