dave charbauski caterpillar inc. (retired) · • finish stock • amount can vary with material...
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www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
What’s Driving the Cost of
Your Casting?
Dave Charbauski
Caterpillar Inc. (Retired)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Personal Profile
Current: Casting Quality and Sourcing Consultant
Experience: 22 Years at Caterpillar • Purchasing & Supplier Quality
17 Years in Foundry Management• Iron, Steel & Nonferrous Castings
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Target Cost:X
Has This Ever Happened To You?
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Target Cost:X
Supplier A + 45%
Supplier B + 55%
Supplier C + 40%
Quotes Received
Has This Ever Happened To You?
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Target Cost:X
Supplier A + 45%
Supplier B + 55%
Supplier C + 40%
Quotes Received
?
Has This Ever Happened To You?
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What do you do next?
Options
1. Find a new supply base
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What do you do next?
Options
1. Find a new supply base
2. Go into the Foundry business yourself
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What do you do next?
Options
1. Find a new supply base
2. Go into the Foundry business yourself
3. Investigate your design for cost drivers
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
What do you do next?
Options
1. Find a new supply base
2. Go into the Foundry business yourself
3. Investigate your design for cost drivers
Why should I look at the design?
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Design 5%
Material 50%
Labor 15%
Overhead 30%
Initial Effect
Design Impact on Product Cost Over Time
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Design 5%
Material 50%
Labor 15%
Overhead 30%
Initial Effect Long Term Effect
Design 70%
Material 20%
Labor 5%Overhead 5%
Design Impact on Product Cost Over Time
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Design 5%
Material 50%
Labor 15%
Overhead 30%
Initial Effect Long Term Effect
Design 70%
Material 20%
Labor 5%Overhead 5%
Design Impact on Product Cost Over Time
Potential Casting Impacts
• Higher Scrap Rates
• Increased Rework
• Delivery Problems
• Increased Costs
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Reality Check
Does the part fit the foundry?
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Reality Check
Does the part fit the foundry?
Metal Type• Standard grade or unique chemistry?
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Reality Check
Does the part fit the foundry?
Metal Type• Standard grade or unique chemistry?
• Would changing to a standard grade meet your requirements?
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Metal Type• Standard grade or unique chemistry?
• Would changing to a standard grade meet your requirements?• Could a lower cost material be utilized?
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Metal Type• Standard grade or unique chemistry?
• Would changing to a standard grade meet your requirements?• Could a lower cost material be utilized?
• Commonly poured or periodically scheduled?
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Reality Check
Does the part fit the foundry?
Casting Weight and Size• How well does your casting fit within the foundry’s weight
and size parameters?
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Reality Check
Does the part fit the foundry?
Casting Weight and Size• How well does your casting fit within the foundry’s weight
and size parameters?• Being on either end of the spectrum can be costly
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Casting Weight and Size• How well does your casting fit within the foundry’s weight
and size parameters?• Being on either end of the spectrum can be costly
• Smaller/lighter castings may experience higher levels of scrap due to shakeout damage.
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Casting Weight and Size• How well does your casting fit within the foundry’s weight
and size parameters?• Being on either end of the spectrum can be costly
• Smaller/lighter castings may experience higher levels of scrap due to shakeout damage.
• Larger/heavier castings may require extended cooling time causing a slow down on an automated line.
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Reality Check
Does the part fit the foundry?
Annual Volume• How many pieces do you plan on buying per year?
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Reality Check
Does the part fit the foundry?
Annual Volume• How many pieces do you plan on buying per year?
• Small lot sizes can be difficult in a high production foundry.
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Reality Check
Does the part fit the foundry?
Annual Volume• How many pieces do you plan on buying per year?
• Small lot sizes can be difficult in a high production foundry.
• How many orders per year?
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Reality Check
Does the part fit the foundry?
Annual Volume• How many pieces do you plan on buying per year?
• Small lot sizes can be difficult in a high production foundry.
• How many orders per year?
• Consult with your foundry to determine if your volume is considered low, medium, or high.
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OK - Everything fits! What’s next?
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OK - Everything fits! What’s next?
Time to dig deeper into the casting design to identify
cost drivers
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Draft angles and finish stock allowance• Draft
• Excess draft can add weight• Insufficient draft can increase scrap and rework
• Most foundries need 1 to 2 degrees
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Draft angles and finish stock allowance• Draft
• Excess draft can add weight• Insufficient draft can increase scrap and rework
• Most foundries need 1 to 2 degrees
• Finish Stock• Amount can vary with material type, casting size, and molding
process• Excess stock adds weight and increases machining costs• Insufficient stock can shorten insert life and increase scrap due to
tool breakage and non clean-up
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Parting lines• Flat, straight partings lines are a best practice
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Parting lines• Flat, straight partings lines are a best practice• Offset parting lines are common, but…
• Can increase pattern cost• Are more likely to produce parting fins• Can cause mold compaction issues
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Parting lines• Flat, straight partings lines are a best practice• Offset parting lines are common, but…
• Can increase pattern cost• Are more likely to produce parting fins• Can cause mold compaction issues
• Can you minimize the effect of the parting line?
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Parting lines• Flat, straight partings lines are a best practice• Offset parting lines are common, but…
• Can increase pattern cost• Are more likely to produce parting fins• Can cause mold compaction issues
• Can you minimize the effect of the parting line?
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Cores• Look for ways to minimize or eliminate cores
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Cores• Look for ways to minimize or eliminate cores• Can you incorporate several cores into one?
• Be aware of the assembly cost• Make sure the assembly is robust
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Cores• Look for ways to minimize or eliminate cores• Can you incorporate several cores into one?
• Be aware of the assembly cost• Make sure the assembly is robust
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Cores• Long cores may require chaplets for support
• Cost for chaplet, placement, and finishing• Potential for increased scrap rate
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Section Thickness• Thin sections
• Can be susceptible to misrun and cracking
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Section Thickness• Thin sections
• Can be susceptible to misrun and cracking
• Thick sections• May be prone to shrinkage problems
• Isolated heavy sections should be avoided
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Section Thickness• Thin sections
• Can be susceptible to misrun and cracking
• Thick sections• May be prone to shrinkage problems
• Isolated heavy sections should be avoided
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Section Thickness• Variations in wall thickness can lead to higher scrap rates
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Section Thickness• Variations in wall thickness can lead to higher scrap rates• Transition design
• Abrupt transitions are stress raisers
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Section Thickness• Variations in wall thickness can lead to higher scrap rates• Transition design
• Abrupt transitions are stress raisers
Which transition is best?
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Finishing Requirements• How clear are your finishing instructions?
• Over processing leads to waste
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Finishing Requirements• How clear are your finishing instructions?
• Over processing leads to waste
• Grinding• Does the parting line need to be ground flush?
• Can the foundry design the pattern to eliminate the need for parting line grinding?
• Can raised pads be used for riser and ingate connections?
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Finishing Requirements• How clear are your finishing instructions?
• Over processing leads to waste
• Grinding• Does the parting line need to be ground flush?
• Can the foundry design the pattern to eliminate the need for parting line grinding?
• Can raised pads be used for riser and ingate connections?
• Cleaning• Is re-blast after grinding necessary?• Cleanliness of internal passages
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Finishing Requirements• How clear are your finishing instructions?
• Over processing leads to waste
• Grinding• Does the parting line need to be ground flush?
• Can the foundry design the pattern to eliminate the need for parting line grinding?
• Can raised pads be used for riser and ingate connections?
• Cleaning• Is re-blast after grinding necessary?• Cleanliness of internal passages
• Packaging • All specific needs should be known before the quoting stage
• Paint, container type, rust protection, packaging methods
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Surface Finish Requirements• Must be defined early in the design process
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Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?
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Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
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Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
• Process can be engineered to minimize problems
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Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
• Process can be engineered to minimize problems
• Use surface finish comparators • C9 Microfinish Comparator
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Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
• Process can be engineered to minimize problems
• Use surface finish comparators • C9 Microfinish Comparator• SCRATA plates
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
• Process can be engineered to minimize problems
• Use surface finish comparators • C9 Microfinish Comparator• SCRATA plates• MSS SP-55
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Tolerances• Cast tolerances are influenced by many factors -
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Tolerances• Cast tolerances are influenced by many factors -
• Metal type
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Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process
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Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process• Size and weight of the casting
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Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process• Size and weight of the casting
• Follow industry standards whenever possible
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Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process• Size and weight of the casting
• Follow industry standards whenever possible
• Pattern considerations• Materials
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Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process• Size and weight of the casting
• Follow industry standards whenever possible
• Pattern considerations• Materials• Construction method• Pattern cost vs Dimensional stability
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Inspection Requirements• Understand the basic inspections that will be performed
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Inspection Requirements• Understand the basic inspections that will be performed
• Typically a Brinell audit
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Inspection Requirements• Understand the basic inspections that will be performed
• Typically a Brinell audit• Magnetic particle
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Inspection Requirements• Understand the basic inspections that will be performed
• Typically a Brinell audit• Magnetic particle
• Additional inspection
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Inspection Requirements• Understand the basic inspections that will be performed
• Typically a Brinell audit• Magnetic particle
• Additional inspection• Material certifications• Hardness testing• Ultrasonic inspection• Radiography• Pressure testing
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Keys to Success
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Keys to Success
Goal is to eliminate or minimize cost drivers before the design is finalized
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Keys to Success
Goal is to eliminate or minimize cost drivers before the design is finalized
Early Foundry Involvement• Start at the concept phase if possible
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Keys to Success
Goal is to eliminate or minimize cost drivers before the design is finalized
Early Foundry Involvement• Start at the concept phase if possible
Collaboration• Make sure your needs and expectations are known
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Keys to Success
Goal is to eliminate or minimize cost drivers before the design is finalized
Early Foundry Involvement• Start at the concept phase if possible
Collaboration• Make sure your needs and expectations are known
Design Reviews• Everyone touching the part should be involved
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