and communicates control dimensions from the perspective of machinability, product assembly and in-service func- tion of the end item. Rather than create this SQP in a


vacuum, the producibility engineer develops the control dimensions in conjunction with the casting engi- neer to ensure key characteristics are understood and controls are well designed into the casting process. When appropriate, additional tooling and fi xtures are developed for met- alcasting use during production and inspection operations.


Meeting Customer Expectations


Experienced metalcasters appreci-


ate that all suppliers are not created equal. Each operation brings diff er- ent processes and experience toward solving customer challenges. Alloy and process diff erences aside, suppli- ers have signifi cant niche capabili- ties in terms of rapid prototyping, mechanical property requirements, size, complexity and other aspects of product confi guration. T is requires an appreciation for how these capa- bilities infl uence the best fi t within the OEM’s supplier base for each casting application. T e Raytheon North Texas


organization uses a casting team to coordinate the strategic issues of process enablers, preferred supplier list, supplier development and technol- ogy roadmaps to ensure the interests of each organization remain balanced throughout the procurement process and casting production life cycle. Key stakeholders include the producibility engineering (representing design), supplier quality engineering and sup- ply chain management. Looking back, the LRAS3 sensor


housing remains a state-of-the-art casting with an incredibly complex die set, a tedious wax injection operation, and a demand for precision at every subsequent step in the process. But the results justify these eff orts. Four suppliers—Shellcast, GSC, Alcoa Howmet Laval and Uni-Cast—have produced more than 5,500 castings over the product life to date. T e design and development eff orts


Jul/Aug 2013 | METAL CASTING DESIGN & PURCHASING | 25


of Raytheon experts, supplier team- mates and customers were paramount. As a result, the LRAS3 system per- forms well and the cast housing struc- ture continues to meet all objectives. T e lessons learned are collected by the casting team for use in each subsequent


casting development project. T e Ray- theon Casting Product Development Process (Fig. 6) continues to serve as the template for success in design and development of complex metal castings. T e next challenge is to make them cheaper, faster and better. 


Figure 6. The casting development process feeds mechanical development.


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