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Pacific Steel Casting CompanyEst. 1934Est. 1934

Robert MurilloPacific Steel Casting Company

Facilities ManagerMarch 8th, 2012

Facilities Management of a Facilities Management of a Steel Casting CompanySteel Casting Company

Carbon Steel vs Cast Iron

• Carbon content <2%• Steel is an alloy of iron,

carbon, nickel, chrome, vanadium, etc…

• Types: Low, Medium, High, and Ultra-High Strengths

• Carbon Content >2%• Cast Iron is basically

carbon, iron, silicon.• Types: Gray, White,

Malleable, and Ductile.

Pacific Steel CastingIn a Nut Shell

• Plant 1 opened in 1934.• Plant 2 opened in 1975.• Plant 3 opened in 1982.• Each plant equipped with state of the art environmental controls.• 3 Carbon filtration systems to remove VOC from process.• Facility has the ability to demand 9+ Mega Watts during steel

production.• Recycles over 2,000+ tons of scrap metal a month.• Recycles all process materials either internally or through outside

vendors.• Largest industries serviced are Oil Tool and Industrial Trucking.• Combined plant production capacity of 2000+ tons/month.

3 Production Facilities

Sand Molding Types:• Green Sand• Shell• Air-Set

Overview of Steel Casting Production Process

My Background• Completed trade school and

became a Certified Welder.• Graduated Butte College with

an AS Degree in Welding Technology.

• Graduated CSUChico with a BS in Manufacturing Technology with a minor in Production Operations Management.

• Worked through college as a Fabricator/Machinist.

• Hired by Pacific Steel Casting in 2004 as a CAD operator.

• Promoted to Robotics Engineer.• Promoted to Plant Engineer.• Promoted to Facilities Manager.

Professional Organizations-•American Welding Society (AWS)•Society of Manufacturing Engineers (SME)•American Foundry Society (AFS)•Steel Founders Society of America (SFSA)

Western Division Chairman

Awards and Achievements-•Westec College Challenge – Grand Prize•Technical Paper Published in Modern Casting Magazine ‘Minimizing Power Demand on Electric Arc Furnaces’.

Facilities Management

• Maintenance Departments• Operating Budget• Equipment Design and

Engineering• Environmental Responsibility• Capital Equipment

Installation/Project Management• CalOSHA Compliance• Safety/Technical Training• City of Berkeley• Energy Management• Facility Security

Projects• EAF Dust Collector

Projects• EAF Energy Demand Reduction

Furnace#1

Furnace#2

Furnace#3

PC

PC

Plant 3 Furnace Contro ller

P lant 2 Furnace Contro ller

P lant 1 Furnace Contro ller

E lectric ityM eter

E lectric ityM eter

E lectric ityM eter

RheostatContro ller

RheostatContro ller

Energy D irector

Energy D irector

Energy D irector

Projects• LN8 Shot Blast Machine

Continuous Improvement

• Lean Manufacturing Implementation• 5S Projects• TPM – Total Productive

Maintenance

• Preventative Maintenance• Predictive Maintenance• Root Cause Analysis

Quiz

• What year did PSC first open for business?

• What is PSC’s combined production capacity (tons)?

• How much power demand does this facility require?

• What does PSC call our VOC filtering equipment?

• What are the two main industries PSC services?