top of page
Sichtkontrolle.jpeg

Grey & Ductile
Iron Castings

To transform the client’s Grey & Ductile Iron Foundry into a world-class, highly profitable operation by deploying best-in-class practices in process excellence, quality leadership, technology modernization, cost optimization, and organizational capability building.

Key Areas of Work

1. Strategic Diagnostic and Benchmarking

  • Conduct a comprehensive audit of current foundry operations: production, quality, maintenance, supply chain, energy usage, and workforce practices.

  • Benchmark against global best practices (top-performing foundries internationally).

  • Identify critical performance gaps (productivity, yield, cost structure, delivery, quality).

2. Foundry Process Optimization

  • Redesign and standardize key processes (molding, melting, pouring, cooling, fettling, machining) for best quality and throughput.

  • Optimize metallurgy and charge mix designs to maximize yield and minimize raw material cost.

  • Reduce scrap and rework rates through real-time quality control systems and Root Cause Analysis (RCA).

3. Quality Excellence and Zero Defect Culture

  • Deploy a robust Quality Management System (QMS) aligned with ISO 9001/IATF 16949 (if automotive).

  • Implement in-process quality control (IPQC) and Statistical Process Control (SPC).

  • Drive "Zero Defect" mindset with mistake-proofing (Poka-Yoke), First Time Right (FTR) initiatives, and final inspection improvements.

4. Energy and Cost Optimization

  • Perform detailed energy audits (furnace, compressor, sand plant, etc.).

  • Optimize energy consumption per ton of casting produced (target kWh/ton improvements).

Streamline supply chain and procurement strategies to reduce working capital and raw material costs.

5. Lean Manufacturing and Productivity Improvement

  • Introduce Lean methodologies (5S, SMED, Kanban, Value Stream Mapping) across the foundry.

  • Improve equipment uptime using Total Productive Maintenance (TPM).

  • Introduce real-time monitoring systems for productivity, OEE (Overall Equipment Effectiveness), and process stability.

6. Digitalization and Smart Foundry Initiatives

  • Guide adoption of Industry 4.0 technologies like IoT sensors, digital quality tracking, furnace automation, sand control systems, and predictive maintenance.

  • Deploy data dashboards for monitoring scrap rates, cycle times, downtime, and energy consumption.

7. Workforce Development and Cultural Transformation

  • Build Foundry Excellence Teams (cross-functional task forces).

  • Conduct continuous training in best practices, quality control, problem-solving (e.g., 8D, A3 thinking), and operational leadership.

  • Establish a performance-driven, high-engagement culture through skill matrices, rewards systems, and accountability frameworks.

8. Business Growth and Customer Diversification

  • Support in improving delivery performance (OTIF - On-Time In-Full) to become a preferred supplier.

  • Identify opportunities to diversify customer base (e.g., move into higher-margin sectors like non automotive, hydraulics, energy parts).

  • Develop business strategies for scaling profitably and sustainably.

bottom of page