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had just made electrical updates, so D&L sent a crew out to recover a significant amount of that infra- structure for the new facility. Te conveyor system was another


area where employees played a large part. “We built many of the conveyor units or modified ones from else- where and assembled with our staff here,” said McGowan. “It all came around by our ingenuity and willing- ness to look at things differently.”


“The pouring operation is very similar to the other facility, but in mold handling, we chose a more modern approach in using all elec- tric drives and positioning systems,” said McGowan. D&L did all of its own electrical controls and a computerized monitoring system. “We have anything from our muller to how our sand is being controlled to what parts we’re to be running, our production schedule, the dif-


ferent pieces of equipment to the overall status of the facility,” said McGowan. “It’s very similar to what we’re already doing in the other building, so anybody can come look at this screen and have an immedi- ate status of what’s going on in the area.” They can track reject rates and we can base process improvements and maintenance plans on the data. “It helps us have good communica- tion over multiple shifts,” he added. Using components common to those in the existing plant, from gear boxes to drive systems and wear parts, simplifies maintenance and repairs. While the new, 31,000-sq.-ft.,


facility is a standalone operation for larger castings, using a 54-sq.-in. flask, it integrates with D&L’s exist- ing machining, finishing, shipping and other departments. “The old plant uses 42 and


36-inch flasks,” said McGowan. “With more and more underground construction, utilities for example putting more underground, there’s been a trend toward larger castings. It’s the same customers but their demands have been changing. That’s what drove us to add the larger flask size. But now we have an opportu- nity to do more with it.”


Greater Capacity and Poised for Growth


It’s been a year since the new


facility poured its first casting. Today, D&L Foundry & Supply’s operations can produce up to 140 tons of castings a day for its custom- ers on the West Coast. “We’ll probably do about 52


million pounds this year,” said McGowan. “We still have a third shift to fill as demand increases, and there are improvements we can make, but it’s added some capac- ity and really opened up some good markets for us.” Te original expansion plan was


The new operation combines used, new and staff-built equipment including this sand system and a complex assembly of conveyors.


24 | MODERN CASTING February 2015


based on the demand from munici- palities with larger sizes D&L hadn’t been able to cast. And the new facility has not only allowed them to engage in those markets, but to diversify into new jobs outside


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