figure into the lead time calculation. “Delivery times are affected if you
have to run the parts twice,” Howell said. “We do parts for the U.S. Navy, and they sometimes don’t understand that deliveries are slow because they put difficult requirements on the parts. So, it’s not just the time to do the X- ray testing, but also some time to make the additional parts.” In some specifications, the term
“foundry control” is used. This is where the metalcasting facility performs all required inspections on preproduction castings. If failures occur, the metalcaster adjusts the gating and riser design for other batches of castings until 100% of the castings pass all of the inspections. Then the casting facility will run the balance of the order. “Establishment of foundry
control means if we pour the metal at this temperature with this gating and riser setup, the parts will pass,” Howell said. “The foundry agrees it won’t change the technique. It might take a week or two up front, but you save time and money by establishing foundry control instead of needing a certain amount of X-ray inspection for every lot of parts that are cast.”
ing, painting, assembly or other addi- tional services means you don’t have to deal with those additional vendors. Te casting supplier will do the work for you, but it will add to how long it will take to receive delivery of your parts. And if the metalcaster is outsourcing the services, they will be susceptible to those lead times, as well. “We have started asking our sup- pliers to give us their lead times so we can build in the amount of time to finish the parts,” Peaslee said. “We have had to put in a system to track those casting to make sure they are staying on schedule. Not a whole lot of people out there paint or heat treat, so they do get backed up.” Metalcasters want to stick to the
8
schedule they have established so they can operate efficiently and deliver
Mar/Apr 2015 | METAL CASTING DESIGN & PURCHASING | 41
Number of value-added services provided. A metalcasting facility
that can handle the machin-
“
When the chips are down, we can work over time and negotiate faster deliveries from heat treaters and inspection labs...We can fast track parts for an additional price.” —DAVID HOWELL, ALUMALLOY CO. INC.
parts to all their customers in a timely fashion, but many will help out a good customer with an emergency order when they are in a pinch. “When the chips are down, we can
work over time and negotiate faster deliveries from heat treaters and in- spection labs. We have customers who often need a few castings quickly for a show. We can fast track their parts for an additional price,” Howell said. “As long as it is a single run, we can usually do it.” A good relationship with your
supplier will help your case for those times you need parts sooner than the metalcaster’s published lead time. “Casting buyers don’t buy castings
from foundries. Tey buy castings from people who operate foundries. If casting buyers have a good relationship with those people, they will find their lead time, collaboration, everything, is better,” Boyd Jr. said. “If casting buyers think they are just dealing with an impersonal entity they are likely to find they are treated the same way. Relationships matter.”
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