2017 METALCASTER PROSPECTUS Waupaca Foundry Mission Statement


Waupaca Foundry produces iron castings, focusing on transportation, construction, agriculture and industrial markets worldwide.


We embrace lean manufacturing tech- niques in all our facilities, and manage other value added services for our cus- tomers. Our customers’ expectations are met through innovative technol- ogy, continuous improvement culture, and the efforts of our dedicated, motivated, highly-trained workforce.


We maintain strong social and


environmental commitments to our employees and communities, including: improvements sustained through green initiatives, a well maintained and safe environment and the encouragement of employee’s personal growth through advancement and continuing education.


Metals


Gray Iron, Ductile Iron, Austempered Ductile Iron


Processes


Vertical and Horizontal Green Sand Molding


Waupaca Foundry Plant 1


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


Waupaca Foundry Plant 2/3 1955 Brunner Dr., P.O. Box 249 Waupaca, WI 54981


Waupaca Foundry Plant 4 805 Ogden Ave.


Marinette, WI 54143 Waupaca Foundry Plant 5


9856 State Highway 66, P.O. Box 189 Tell City, IN 47586


Waupaca Foundry Plant 6


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


Waupaca Foundry - Effi ngham 1500 Heartland Blvd. Effi ngham, IL 62401


Waupaca Foundry - Wellsboro 9728 Route 287


Wellsboro, PA 16901


Waupaca Foundry - Lawrenceville 18986 Route 287


Lawrenceville, PA 16929 www.waupacafoundry.com METAL CASTING DESIGN & PURCHASING / 2017 Metalcaster Prospectus 19


Waupaca Foundry, a Hitachi Metals Group company, 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 Waupaca Foundry from the rest. We hold ourselves to a higher standard. And we stand by it, producing the most consistent, high-quality iron castings in the world. Waupaca Foundry has headquarters and


three foundries in Waupaca, Wisconsin, as well as operations in Marinette, Wisconsin, Tell City, Indiana, Etowah, Tennessee, and Lawrenceville, Pennsylvania Additionally, it has machining and assembly operations in Effi ngham, Illinois, and Wellsboro, Pennsylvania Waupaca Foundry operates seven foundries and two machining and assembly plants and employs more than 4,385 people. Waupaca Foundry produces gray iron, ductile iron, austempered ductile iron, and compacted graphite iron castings, melting more than 10,000 tons a day. Castings up to 350 pounds or 160 kilograms are produced using one of our 35 vertically parted high pressure molding machines by a workforce that puts generations of iron casting expertise to work for our customers every day.


Our Process


Since establishment in 1955, Waupaca Foundry is continuously improving in the areas of safety, quality, productivity, and reli- ability. Our innovative thinking is a large part of how we’ve led the industry in delivering consistent high-quality castings. Waupaca Foundry’s design engineering, high volume melting capabilities, cus- tom vertical green sand molding equipment, and automated


fi nishing systems minimize post-process ma- chining requirements and maintains controlled chemistry for consistent machining—all result- ing in best-in-class iron castings.


Our Technology Waupaca Foundry’s top leaders, manufac- turing teams, engineers, and metallurgists 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, additives, 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 designs and weight reduction to meet today’s demands. 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 Waupaca Foundry 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, carefully produced on our custom molding machines and fi nished and cleaned using our automated 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.waupacafoundry.com.


For more information, please visit www.waupacafoundry.com.


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