Rising to the Challenge
An NFCA client had severe quality issues from another supplier. The part (a water outlet) was being produced as a low-pressure, permanent mold casting. The Tier I supplier was machining this thin wall (.180”) complex shape casting that required a sand core. There was extensive machining on the part which was 100% leak tested after machining by the customer. Impregnation was not allowed.
Several suppliers had already attempted to produce this part in Tilt Pour and Low Pressure Permanent Mold. The best they could do 10% foundry scrap after machining. And of course, the casting supplier wanted a price increase of 30%.
NFCA accepted the challenge. Through the use of simulation modeling, it was determined that several external design changes were required. With approval from the OEM customer the changes were implemented. Within 6 months NFCA produced this part and continued for over 6 years with volumes averaging 240,000 parts annually. Foundry scrap after machining was ?less than 4%.
Reducing Cost with Sand Casting
As a result NFCA’s Tier I supplier reduced their machining scrap from 10% to less than .5%, avoided a 30% price increase and satisfied their major targeted customer. NFCA’s internal scrap was less than 5% and productivity was improved compared to the permanent mold supplier by more than 700%.
Shipments went from the three daily shipments by previous supplier, to truckload quantities from NFCA delivered weekly.
The bottom line: A successful partnership through Casting Excellence
Casting Wt: 1.66 lbs. Minimum wall thickness: .180” (4.6mm)
Automatic green sand molding with sand core
Requirements: 100% leak test after extensive machining
No impregnation allowed