We develop projects in close cooperation with our client’s staff, from conceptual engineering and detailed design, to ensure that client’s requirements are met. We never request investment in production equipmen at the beginning of the project. Via knowledge deployment we make all facilities (melting shop, melt transport and treatment, pouring, molding machine, sand shop, core shop, gating and feeding system design, etc.) to perform at their best. Only when a bottle neck is detected an investment will be suggested based on demonstrated full skill abilities to run this new equipment efficiently and on improved performance and revenue targeted. Our involvement begins with an operational survey that examines the facilities and performance levels at key points in the metal casting process. From our knowledge of international best practices, we identify areas with room for improvement and suggest appropriate ad-hoc projects (with cost/benefit indicators). We assist with the implementation of our recommendations via turnkey collaboration, working closely with the management and staff of our client to monitor the project till the agreed improvements are achieved. Tailored training is provided in metallurgy, equipment efficiency optimization, sand preparation, core production, gating and feeding design, state of the art technology, etc., on demand.
The success of the projects is measured through the following indicators:
- Technology and procedures: process yield, operational equipment efficiency (OEE)
- Products and technology: energy consumption, new sand consumption, casting rework, scrap rate
- Organization and equipment: labor productivity, total effective equipment performance (TEEP)
Working procedure Step 1. Technical and organizational survey + report with strong and weak points. In this step, gathering and documenting of clients’ needs and requirements are performed. A technical survey is conducted (2-3 days depending on the size of the company). Conclusions are presented with concise insights and recommendations. The room for improvement of the key points of the process/product is also provided to disclose technological performance of the company in the global market (how far the company is from the best in class). Step 2. Proposal for a collaboration project + discussions till agreement is achieved + scope + timing + milestones + quotation In this step CASTIRGALU foundry consultants interface directly with management and staff of the client to proactively communicate and create brainstorming workshops to establish the appropriate layout of the project, the scope and the assistance needed. Once everything is discussed and agreed a quotation can be delivered to the client. These projects are always collaborative to be sure that the knowledge remains in the company. Engagement of the management and follow-up meetings are essential. At the end of the project, a complete report which includes all activities, analyses, insights, conclusions, achieved goals and future recommendations, together with executive-level presentation, is delivered.
