TPM Conversion from Sand Casting is the One of Many for Customer


It started as a simple discussion with


a customer that ended in Texas Precision Metalcraft (TPM) taking on a project to convert a sand casting into investment casting. The project resulted in tremen- dous savings for the customer, but that's just the beginning. Since then, TPM has converted 29 parts for the same customer, with more planned in the coming year. One example is a 4" spring case


which TPM Sales Manager Steve Jaro- szewski indicated was originally a heav- ily machined sand casting. "We quoted the part machined com-


pete, which right off the bat presented a huge advantage for them," Jarosze- wksi said. "They were receiving non- machined sand castings, then machining them and scrapping more than 20% for internal casting issues." "Porosity was the biggest problem,


and since it didn't show up until far into the machining process, many wasted man hours were expected and accepted as the rule," he added. "This drove the price of their sand castings up and destroyed lead times."


"The initial reaction to the new in-


vestment castings was 'WOW, what a dif- ference in appearance'. The investment cast parts fit better, weighed about 15% less than before, looked much nicer, and cost significantly less with the elimina- tion of significant machining and scrap." After converting 29 parts to invest-


ment castings, the customer reported a savings of more than $350,000 last year alone. They went from over 20% scrap rate down to 0%, and shaved eight weeks off their promise dates to their customers. "The 4” spring case alone saved


11.25 machining man hours per part. The savings quickly started adding up, just a little over $1000 per part," he added. "TPM has learned that this customer is expected to move at least five parts per quarter from sand to investment castings in 2011," Jaroszewski said. "The custom- er’s division has informed other branches of their discovery and we are now quot- ing conversions for them as well.


January 2011 Texas Precision Metalcraft


♦ Quality ♦ Craftsmanship ♦ Reliability


♦ Customer focused ♦ Solution driven ♦ Value proven


Phone: 281/240-9191 Email: info@txpm.com


Fax: 281/240-2472 Web Site: www.txpm.com 19


TPM President Jerry Connor indi-


cated this project began because of a sim- ple conversation and a good relationship with the customer, a relationship which is even stronger now. The end result was a


win-win situation for all. Sometimes it pays to take a new look at an old prob- lem. Connor notes other potential cus- tomers like this are out there. TPM plans to find them.


This investment casting is a conver- sion from a sand casting which was heavily machined. It represents a growing number of conversions which TPM has received from the same customer. This project alone saved 11.25 machining man hours per part. The savings quickly started adding up, just a little over $1000 per part.


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