Fall River Group, which includes diecasting and machining operations, employs 250 people, with 140 at its sand casting facility.


design, build and installation, was initially scheduled to meet Fall River’s requirements. Equipment supply is typically in the range of 30-32 weeks with a confirmed design, yet this project needed a custom mold handling solution, which would normally extend this timeline. The project was sped up by closely coordinated engineering efforts from Fall River and EMI. Installation time was reduced by planning all the machine’s


hydraulic and pneumatic manifold locations with pre-piped locations, implementing pre-wired Harding connectors for all electrical connec- tions, and confirming all foundation pads locations with embedded plates to eliminate the need for grouting. These efforts resulted in a quick installation and start up in less than a month after shipping. “It was as close as you could


come to plug-and-play,” Weigel said. “We’ve got a great industrial engineer


“Te added capacity allowed us to handle the additional demands on sand prepping and cooling. All the while, we could prepare for a faster conversion to the new system so our operations could continue virtually as-is.”—John Vick, Fall River Foundry


32 | MODERN CASTING October 2015


that worked with EMI. We had the computer-generated drawings so we could overlay all the footprints. It was surprisingly seamless.” Fall River’s primary operator was


trained to use the new equipment alongside the provider’s technician. Te expected bugs with starting up such a significant operation were worked out while the casting facility improved production speed on the new line. Only a few existing jobs were


retooled for the new line, with Fall River preferring to pursue orders from both new and existing customers. Te installation of the new automatic molding line has boosted total produc- tion at Fall River’s facility by 12.5% with additional capacity available to produce more. “We’ve seen orders from both


new and existing customers,” said Scott Sitkin, sales manager. “We have a lot of existing customers who are realizing we can fill specific orders. We’re also seeing new cus- tomers approach us to quote projects we previously wouldn’t have been able to handle.”


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