purchasing points P The Loss of Experienced Professionals


in the U.S. Metalcasting Industry Bob Mueller Jr., Joy Global Surface Mining, Milwaukee


of conversation was the aging work force, particularly in the management and technical areas of the industry. During my career in metalcasting,


I


I worked with some “seasoned” veter- ans of the industry. T ese experienced individuals seemed to have the solu- tion for every possible situation that would come up. T ey could correctly troubleshoot any quality problem, devise a method to cast even the toughest component and develop cost improvement opportunities for their custom- ers. I watched, listened and learned from these mentors who provided me an educational experience that cannot be replaced. I was one of the fortunate ones. Today, in my current role, I


recently attended a metalcast- ing conference in Chicago and had a chance to speak with many metalcasters from that region. A common point


T is situation might have worked


then, but what happens when sea- soned veterans retire? T e population of these masters of the art is declin- ing every year, and the void they are leaving should be a concern for both their customers and the U.S. metalcasting industry as a whole. T e industry has the most experienced group of metalcasters in the world, but we are losing them faster than we are replacing them. As an OEM customer with sig-


nifi cant casting purchases, this trend is “


have had the opportunity to visit metalcasters all over the United States. A majority of these facilities also have their share of “seasoned veterans” providing guidance in all areas of their plants. When I fi rst traveled to my new suppliers, it was easy to identify these key players and the role they provided to their respected facilities. I quickly aligned myself with them to tap into their knowledge and identify what they off er to add value to our relationship. In many cases, they were working as lone wolves with no one along side them to learn from their mastery of the industry.


Metalcasting customers rely on their supplier facilities to not only produce cast components but to be the experts in casting metallurgy, engineering and quality.”


alarming. Metalcasting facilities do not have the luxury of recruiting experienced metalcasters right out of college. Instead they utilize green recruits that must be developed over years, if they stay that long. I have seen little to no examples of employees working in the footprints of seasoned leaders or the apprenticeship programs off ered in the past. So what does this mean for buyers


and OEMs that have come to rely on these professionals? Metal casting customers rely on their supplier facilities to not only produce cast components but to be the experts in casting metallurgy, engineering and quality. With the lack of “casting wise” buyers in the mar- ketplace today, these points are more important now then ever before. Metallurgists are counted on to


provide their customers with experi- enced choices and alternatives to the material they are looking for in their components. T is information does not come from a book; it is developed through applied experiences and years of trials and testing. Customers also rely on foundry engineers to develop pattern tooling and casting processes that provide new parts that are right the fi rst time and existing parts that consistently meet specifi cations. T ey are also the link to improving process- es that can result in better products, at reduced cost. Quality management is a key area customers de- pend upon to assure their cast products meet the print and all specifi cations. Without a


“seasoned” profes- sional on staff at your metal casting facility of choice, your supplier/ven- dor relationship will struggle to provide


any added value. These individuals help make a metalcasting business world class. Take them out of the operation and your relationship will take a dramatic step backward. As procurers of cast products,


we need to ensure our suppliers are looking to the future and utilizing ex- perienced professionals to mentor new employees. T e veterans did not learn all of this overnight and neither will new employees. It has been accumu- lated through years of experience and that experience must be passed along to worthy individuals. Next time, I will discuss some ideas for how this can be accomplished. 


Bob Mueller Jr. is senior supplier quality engineer, cast product and casting supplier development, for Joy Global Surface Mining, Milwaukee. He has more than 30 years of casting experience.


Mar/Apr 2015 | METAL CASTING DESIGN & PURCHASING | 49


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