A NFCA customer 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.
The Tier 1’s existing supplier was providing product with 40% fallout rate after machining and air decay leak test. 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.
Reducing Cost with Sand Casting
As a result NFCA’s Tier 1 supplier reduced their machining scrap from 40% to less than .5%, avoided a 30% price increase and satisfied their major targeted customer. NFCA’s internal scrap was less than 2% 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
All industries seek ways to increase value from their foundry partners. Sand Casting from Non Ferrous Cast Alloys increases value through total cost management and improved manufacturability.
In today's competitive global marketplace, business partners need to meet the customers delivery expectations. Non Ferrous Cast Alloys has company wide resources dedicated to ensuring on-time delivery to meet our customer's delivery expectations every time.