MAY 2021 foundrymag.

com

Cupola System Design

OPTIMIZES
MELTING
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IN THIS ISSUE
HIIHFWLYHO\VHQVLEOHKHDWLVGLUHFWHGWRWKHPROWHQ Lowering the Pressure
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Choosing the Right
Vacuum Impregnation
Program

A New Age for Vintage

Machinery

Anticipating the
Challenges of
Digital Transformation
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Tracing the Sources of No-Bake Curing Variation
Temperature is a critical factor in the determination of work time and strip time (WT/ST),
and temperature-related variables must be controlled as seasonal conditions change.
Q:
process?
Why do we find seasonal variations in curing
speed for our foundry‘s no-bake molding
A: It is not uncommon for foundries to experience
variations in curing speeds in their no-bake lines
as the seasons change. The most likely cause of this
problem are the changes in environmental tempera-
tures and consequently the temperature of molding
sand. Temperature-related variables, which affect reac-
tion speeds and curing times, must be considered as
seasonal conditions change. It is well established that
temperature has a critical role in the determination of
work time and strip time (WT/ST) for the no-bake curing
process.
Ideally, a foundry would maintain a constant sand
temperature to ensure consistent cure times. However,
it is far more practical to alter the catalyst strengths or
quantities. To achieve a desired WT/ST, a balance must
be struck between the temperature of the molding sand
and the quantity and reactivity of the selected catalyst.
The relationship between sand temperature and no-
bake resin reaction times has come to be known col-
loquially as “the 18 degree rule.” This rule describes an
observed trend wherein as the temperature of molding
sand decreases by 18 °F, the reaction time (and strip
time, ST) effectively doubles.
This rule can be explained by the kinetics of the cur-
ing reactions, and what is known as the temperature-
dependent rate constant. Experimentally, for a phenolic
urethane binder system the rate constants generally
follow a standard Arrhenius behavior within a limited
temperature range.1
Alternatively, in chemical reaction kinetics this be-
havior could be expressed through the use of the Q10
temperature coefficient, which is a function of the rates
of a reaction at two different temperatures. Generally,
the former exists as the more common descriptor of
chemical reaction rates a function of temperature. Ex-
perimental modeling concerning the simple reaction
1. Stanko, M.; Stommel, M. “Kinetic Prediction of Fast Curing Polyure-
thane Resins by Model-Free Isoconversional Methods.” Polymers 2018,
10, 698-713.
2. McGinn, C. E.; Spaunburgh, R. G. Symposium on Isocyanate Poly-
mers, American Chemical Society Meeting, Atlantic City, N.J. (Sept. 1956)
F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
ADVERTORIAL
Warut Sintapanon | Dreamstime
By seasonally adjusting catalysts used in the no-bake molding process,
foundries can mitigate the cure-speed changes seen as temperatures
fluctuations.
of diisocyanates with diethylene glycol adipate dem-
onstrated that Arrhenius rate constants increased by a
factor of 1.5-2 every 18 °F, depending on the functional-
ity of the diisocyanate reacted.2 This physically mani-
fests as the aforementioned, temperature-dependent
twofold increase in WT/ST observed in foundries.
It should be noted, however, that this rule is not
unique to phenolic urethane resins. The same behavior
and temperature dependence can be seen across all
no-bake product lines (phenolic urethane, furan, and al-
kaline phenolic), and must be corrected for accordingly.
To accommodate for this behavior, catalyst adjust-
ment can be used to overcome small changes in sand
temperature. It is recommended that foundry operators
consults their supplier to appropriately reevaluate the
strength or quantity of the catalyst in use. Generally, it is
recommended that a greater quantity or more-reactive
catalysts be used in the colder months, while a lower
quantity or less-reactive catalysts be used when the
weather begins to warm.”
By seasonally adjusting the catalyst used in the no-
bake molding process, a foundry can mitigate the cure-
speed changes seen as temperatures fluctuations and
ensure adequate mold quality year-round.
Seek metalcasting solutions … discuss ideas
and new technologies with ASK Chemicals
Join the Conversation …
Sumbit your questions
at www.foundrymag.com
 CASTING TECHNOLOGY
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^ CONTENTS
Volume 149 Number 5

14 MANAGEMENT & TECHNOLOGY

2 SUMMIT PARK DRIVE, SUITE 300
RESEARCH CLEVELAND, OH 44131
14 Lowering the Pressure PH 234/466-0200
on Diecasting Development WWW.FOUNDRYMAG.COM
A new research foundry adopts a series of flexible melting EDITORIAL STAFF
and forming capabilities that suggest a new range of
possibilities for low-pressure diecasting. E DITOR ROBERT BROOKS
rbrooks@endeavorb2b.com
METALLURGY G RAPHICS E DITOR BILL SZILAGYI
18 Cupola System Design Optimizes bszilagyi@endeavorb2b.com
Melting Operations
A cupola’s thermal efficiency determines how effectively
sensible heat is directed to the molten iron, and how much
wasted heat is lost to the furnace, the exhaust gasses, slag, etc.
Maximizing a cupola furnace’s thermal efficiency requires
24
the operator to understand the critical design details.

FINISHING
21 Choosing the Right Vacuum
Impregnation Program
A continuous process and a recoverable sealant transformed
one manufacturer’s in-house impregnation operation by
reducing costs, increasing quality, and improving efficiency.

PROCESS CONTROL
24 The New Age of Vintage Machinery
A control system upgrade has put an automotive supplier’s
+30-year-old diecasting unit at the cutting-edge of digital
ON THE COVER: Design by Bill
process control..
Szilagyi, graphics editor.
32
MARKETING
25 Three Questions Shape Every Marketing Plan
Organizations that communicate clearly have a detailed,
up-to-the-moment understanding of their challenges and
opportunities, and what needs to change.

INFORMATION TECHNOLOGY
32 Anticipating the Challenges
of Digital Transformation
Automation, robotics, sensors, and different software
solutions have completely changed how people interact with
equipment, and how products are created. Manufacturers
face a double-edged sword of risk and reward.

26
Editor’s Note.......................................... 4
Metalcasting News ................................. 6
Newsmakers ........................................ 12
Technical Development ........................ 14 Visit the Foundry Management & Technology
Success Story....................................... 24 website www.foundrymag.com for the online
Message Received ................................ 25 suppliers directory.
New Products ...................................... 26
Product Express ................................... 28
Advertiser Index .................................. 30
Business Staff ...................................... 31
Closing Comment ................................. 32

FOUNDRY MANAGEMENT & TECHNOLOGY (ISSN 0360-8999) is published monthly by Endeavor Business Media, 1233 Janesville Ave, Fort Atkinson, WI, 53538. Periodicals
Postage Paid at Fort Atkinson, WI. and at additional mailing offices. Printed in the U.S.A. Copyright 2021 by Endeavor Business Media. Canadian GST# R126431964. Sub-
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2 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
 ^ EDITOR’S NOTE
Chain Reactions
A
new report on U.S. manufacturing trends and pri-
orities has some provocative insights to the ideas
influencing decision-makers today, and the goals
they claim to have adopted for their organization. The
2021 State of Manufacturing Report released by Fictiv
– a digital sourcing platform for manufactured parts – is
well worth your attention for the way it brings together so
many of the disparate points that compete for primacy in
our attentions and often collide with our agendas.
The report is focused especially on the issue of
supply chains, how well they are performing and how
individual businesses (particularly manufacturers in
automotive, aerospace, medical device, robotics, and
consumer electronics markets) are faring within those
supply chains.
Of course, the Covid-19 pandemic reframed how we
view our roles in society. We had to re-account for our
presence in this life. It forced a singular new objective
into the agenda of every person, and then left us to con-
sider and argue among each other, and to wonder, often
hopelessly, if we were making the right decisions. It
standardized anxiety. There has been, and still remains,
a collapse of priority-setting – individual, communal,
and corporate precedents all being combined and reor-
dered, without a new context that we might build within
and thereby renew individual confidence.
But the pandemic is not the only factor working
against confidence-building – for individuals and or-
ganizations, especially for manufacturers. New ethical
or even moral priorities have been urged on us for de-
cades now, since the start of this century at least. The
pandemic brought no “cease fire” from regulators and
financiers and the demands they make, which influence
so much of what individuals and organizations try to
accomplish for themselves.
From the 2021 State of Manufacturing Report we
learn that 95% of industrial leaders believe the pan-
demic had long-term effects on their businesses, and a
comparable 95% believe that “digital transformation” is
essential to the future success of their business.
A critical point is that the pandemic exposed weak
supply chains: 94% of survey respondents are concerned
about their current supply chains, and 92% say their
supply chains are obstructing new product development.
More encouraging is that large majorities of manu-
facturers aim to “future-proof” their organizations, with
62% pursuing a re-shoring strategy, 89% working to
4 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
Robert Brooks
Editor
adopt “sustainable manufacturing,” and 84% seeking to
implement on-demand manufacturing.
“The overriding takeaway... is that the pandemic
served as a catalyst to turn emerging digital ideas into
strategies that are now irrevocably changing supply
chains,” observed Fictiv CEO Dave Evans.
There is a lot to consider about this view of post-pan-
demic manufacturing, and where and for whom these
new emphases are most applicable, but the clear sug-
gestion is that businesses’ priorities have been reset.
Manufacturing – a sector that for so long emphasized
cost-savings and revenue growth – now seems to have
reoriented itself to new standards of performance.
I am open to persuasion that this is a reliable conclu-
sion from the survey because I believe the disruption
brought on by the pandemic was that profound, espe-
cially in the way that disruption collided with manufac-
turers’ long-standing concerns about skills shortages,
quality control and product liability, and other threats to
the work manufacturers do every day.
However, if the pandemic was the catalyst for any
change in the way that people and organizations plan
their futures, I remain skeptical that they will find their
new objectives so well prepared for them. The promises
of “digitalization” and “sustainability”, and similarly
opaque principles carry a tone of perfectibility that is at
odds with so much of what manufacturers never feel the
need to question. Changing what we believe inevitably
changes what choices we make, and finally who we are.
Metalcasters know that perfection is impossible. As
a community and as individuals they are drawn together
by experience, experience that includes costly failure
as well as reliable routines. Overlaying the experience
there is often a fellowship that supports individuals as
they strive for improvement. Underlying it are the sci-
entific principles that define what is and is not possible,
and what may yet be possible if human nature can with-
stand the inevitable gaps in strength or understanding
that precede failure or disaster.
Those gaps in human nature can be as instructive as
any statistical finding about manufacturers’ agendas
or individual’s goals. The experiences of the past year
will surely change what choices manufacturers make,
but only the inexperienced will change themselves as
a result.
^
METALCASTING NEWS
merly the foundry division of Nidec Min-
ster), and Penn-Mar Castings.
CEO Alex Lawton explained that the for-
mer name had been a temporary placeholder
as the organization was put in place. “We
needed time to define whom we wanted to
be in the marketplace. The future of these
Adding more aluminum and mag-alloy diecasting capacity expands Aludyne’s capabilities for
foundries as a group has become more clear
thin-walled components used for EVs and automotive structures. recently, and now is the perfect time for us
to realign the organization for long-term
growth.”
Aludyne Buys Shiloh Industries’
Lightweight Castings Business

A ludyne – a Michigan-based automotive foundry group – has acquired Shiloh

Industries’ CastLight aluminum diecasting division, expanding its light-
weight parts manufacturing base with new plants in the U.S., China, and Europe.
The buyer also highlighted the new capacity it is gaining for “’high-integrity, thin-
walled components’ to be used in electrified drivetrains, e-motor housings, battery
trays and structural components.” Since 2019 private-equity investor Oakland
No price was reported for the private transaction. Aludyne stated that the com- Standard has added four foundries to C.A.
Lawton Co., and now the portfolio offers iron,
bined organization is expected to generate pro forma revenue over $1 billion. steel, and stainless steel castings across a range
CastLight is a unit of Ohio-based Shiloh Industries that offers high-pressure of sizes.
diecasting and squeeze casting at five U.S. plants, one each in The Netherlands
and Poland, and a Chinese location it opened in 2018. Its products are aluminum- The starting point for the group, C.A. Law-
and magnesium-alloy automotive transmission and structural parts. ton Co., De Pere, WI, foundry produces gray
Shiloh produces stampings, welded blanks, and machined parts for suppliers and ductile-iron castings (500-20,000 lbs.)
for automotive bodies, powertrains, and structural and seating components. It and machined components.
formed CastLight from a series of aluminum and magnesium diecasting oper- In December 2019, C.A. Lawton Co.
ations it acquired in the U.S. and Europe over the past decade. It has not com- ownership group Oakland Standard acquired
mented on the sale. Temperform, a Novi, MI, foundry produc-
Aludyne, at that time called Chassix, was formed in 2013 by a merger of cast- ing smaller (10 to 6,000 lbs.) steel and stain-
ing group SMW Automotive LLC and specialty machining specialist Diversified less-steel castings used in corrosive, high-tem-
Machine Inc. Its current arrangement includes 21 manufacturing plants and four perature applications.
technical centers in nine countries, with approximately 3,500 employees. Capa- In April 2020, Oakland Standard added
bilities include aluminum diecastings and sand castings, as well as ductile-iron Damascus Steel Casting to the portfolio, a
castings for automotive chassis, subframes, and EV/e-mobility systems. New Brighton, PA, producer of high-perfor-
“We welcome the CastLight employees in North America, Europe, and Asia mance steel castings.
to the Aludyne team,” stated Aludyne president and CEO Andreas S. Weller. “To- In July 2020, Oakland Standard pur-
gether we are a stronger company delivering innovative solutions to the mobility chased Midwest Manufacturing & Logistics
industry and meeting the needs of our customers globally.” in Minster, OH, from Nidec Minster Corp.,
a metal forming and machine tool builder
that had operated the plant as an in-house
Ferrous Group Rebrands name: The Lawton Standard Co. The port- iron foundry. The Ohio plant casts gray and
as Lawton Standard Co. folio – known until recently as Specialty ductile iron for large-dimension castings up
Metals HoldCo LLC – includes five metal- to 45,000 lbs., for HVAC, municipal pump

T he ferrous foundry group assembled

over the past two years by private-eq-
uity group Oakland Standard Co. has a new
casting operations, The C.A. Lawton Co.,
Temperform, Damascus Steel Casting Co.,
and C.A. Lawton Co. - Minster, OH (for-
and valve, mining, and power generation
industries.
Earlier this year Oakland Standard pur-

6 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
WORK FASTER. AND SMARTER.
NOT HARDER.

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^ METALCASTING NEWS
chased Penn-Mar Castings in Hanover, PA. That plant uses an air-set,
no-bake molding process to cast parts supplied to refrigeration/air
conditioning, pump/compressor, and motor/generator manufacturers.
Tim Flannery, CFO of The Lawton Standard Co. and a principal at
Oakland Standard Co., stated that the portfolio offers “innovation and
knowledge-sharing across locations. Lawton Standard is implement-
ing the best practices from each location across the entire company.
Together, we’ll work to close the generation gap, raise the talent level
in the foundry space, entice manufacturers to bring more activity and
‘casting spend’ back onshore, and positively impact the communities
in which we live.”
IBC to Supply BeAl Castings for F/A-18s
I BC Advanced Alloys Corp. reports it has new purchase orders
from defense giant Raytheon Technologies for beryllium-alloy
parts for the Advanced Targeting Forward Looking Infrared (AT-
FLIR) system, for the U.S. Navy’s F/A-18 Super Hornet aircraft.
IBC, an investment casting and forged parts producer, indicated
the orders are worth over $1.0 million.
Other terms of the contract were not announced.
The F/A-18 Super Hornet is a multi-role fighter aircraft pro-
duced by Boeing Defense.
IBC Advanced Alloys is the parent company for IBC Engi-
8 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
Raytheon’s Advanced Targeting Forward Looking Infrared (ATFLIR) system.
neered Materials Division, an investment caster in Wilmington,
MA. IBC Engineered Materials has previously produced beryl-
lium-aluminum investment castings as azimuth gimbal housings
for the Electro-Optical Targeting System (EOTS) of Lockheed
Martin’s F-35 Lightning II Joint Strike Fighter.
The ATFLIR is a laser-based, target-locating technology that
integrates EO and IR sensors and can pass tracking and targeting
information to other nodes in a networked battlespace, with speed
and precision.
“We are very pleased to have been chosen by Raytheon to
manufacture these high-performance beryllium-alloy compo-
nents for the F/A-18 Super Hornet’s ATFLIR system,” stated IBC
chairman and CEO Mark Smith. “The extraordinary cost-effec-
tiveness of IBC’s near-net-shape beryllium-aluminum casting
technology continues to attract more business to the company
from both defense and commercial manufacturers.
“Our team is especially proud to be able to manufacture these
strategic components in a manner that strengthens U.S. national
defense capabilities and helps to reduce costs to the U.S. Depart-
ment of Defense,” Smith added.
ExOne Developing 3DP Pod
for Military Use
A dditive manufacturing specialist The ExOne Company is
developing a 3D-printing pod under a U.S. Dept. of Defense
contract, aiming to create a “fully operational, self-contained” op-
eration housed in a shipping container. The $1.6-million Defense
Logistics Agency order seeks a ruggedized binder-jet 3D printer
in a standard shipping container up to 40 feet long, which could be
deployed by land, sea, or air to manufacture parts in combat zones,
for disaster relief, or other remote locations.
In concept, the 3DP pod would allow military personnel to print
a digital file of a damaged part and have a finished product in less
than 48 hours, without conventional tooling. A digital library of parts
for 3D printing can be stored electronically. When a digital file is
unavailable, the item would be 3D-scanned and printed on location.
Parts needed to address particular problems also could be de-
signed digitally and 3D-printed, as needed.
ExOne’s 3D printers produce parts in more than 20 metal, ce-
ramic or composite ma- ons systems; and with
terials. They also print Applied Composites
sand molds. ExOne said – San Diego, a supplier
it is developing a “mili- of complex composite
tary-edition” system ca- parts, assemblies, and
pable of binder-jet print- tooling for aerospace and
ing more than 20 metal, defense systems. AC-
ceramic, and other pow- SD’s Reinforced Ad-
der materials into final ditively Manufactured
products or tooling. The Compression Assisted
u p g r a d e d , c o m m e r- Molding (RAMCAM)
cial-grade 3D-printer system is described as
will have a novel body ExOne is developing a fully operational, self-contained 3D printing “factory” housed in a “an enabler” to the 3DP
shipping container, with a ruggedized and simplified binder-jet printer.
style and other details pod project.
that will make it mili- “We’re excited to
tary-grade. “Binder jet 3D printing is a critical man- collaborate with the U.S. Department of
A further goal is to simplify the printer’s ufacturing technology for military use be- Defense and other partners to make our
operation with adapted software and train- cause of its speed, flexibility of materials, 3D printers more rugged for the military,
ing, for a wide range of operating condi- and ease of use,” stated ExOne CEO John which will also benefit our other manu-
tions, without diminishing final part quality. Hartner. facturing customers. Most importantly, we
The project seeks to simplify how the tech- ExOne is collaborating with Dynovas know that years from now, our technology
nology is used in the field, so the pod can Inc., a specialist in materials engineering will play an important role in filling criti-
be used with minimal technical knowledge. and composites manufacturing for weap- cal needs quickly.”

M AY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 9
^ METALCASTING
WPI Developing
Compact, Mobile
Foundry
M aterials scientists and engineers
at Worcester Polytechnic Institute
(WPI) are working with the U.S. Army
to develop a metalcasting operation suit-
able for mobile manufacturing, so that
military units would be able to produce
parts on locations, to cut wait times for
parts and thereby increase unit readi-
ness and reduce logistical operations and
costs.
The Army’s Expeditionary Lab is
compact enough to fit into a shipping
container or truck, and it can be moved
easily and quickly to bases.
WPI’s research project aims to expand
the Lab’s ability to reuse available scrap
metals to make critically needed replace-
ment parts.
“This could revolutionize the way we
manage wartime operations, reducing our
vulnerability in the field,” stated Jianyu
Liang, professor of mechanical engineer-
ing. “WPI’s research aligns with the Ar-
my’s need to be able to fabricate replace-
ment parts from what would otherwise be
wasted metal at or near soldiers’ point of
deployment to ensure they are prepared at
any time and in any theater.”
WPI project began in 2019 when WPI
and the Army Research Laboratory re-
ceived a $1.15 million award from the
Strategic Environmental Research and
Development Program (SERDP), the
environmental science and technology
program run by the U.S. Departments
of Defense and Energy and the U.S.
Environmental Protection Agency. Re-
searchers were tasked to create an agile
manufacturing process that combines ex-
isting 3D printing technology, metal anal-
ysis equipment, and a casting process, in
which ceramic molds of needed parts are
formed around a plastic pattern that can
be created with 3D printing.
Then, scrap metal of the appropriate
alloys are melted and poured into molds
to create needed parts.
“The project’s innovation is not about
1 0 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
NEWS
molds to create parts) for the military; de-
signed models to create new alloys from
waste metals for anticipated spare parts;
and created a compactable, 3D-print-
ing-enabled rapid-casting steel foundry.
They also have developed methods
that Army technicians may use to deter-
mine which alloys are needed to make
particular replacement parts, and to iden-
tify and extract those alloys from avail-
able scrap. The technicians will be able
the tools,” according to Liang. “It’s about to consult a metal-blending model linked
creating a new process that can use ex- to a database WPI researchers have cre-
isting tools and technology to create a ated based on analysis of military scrap
mobile foundry that can rapidly produce metals, to detail the metallurgical compo-
a needed part. This innovation has the sition of parts most commonly in need of
potential to change military logistics replacement or repair.
and modern manufacturing by combin- Also, the WPI researchers developed a
ing multiple tools and processing stages process to prescribe the post-casting heat-
that are typically carried out in separate treatment for specific parts to be made.
locations and facilities into a single, inte- “Our process has led to the creation of
grated system that can be set up and op- a manufacturing unit with a much smaller
erated in the field. Making it compact and footprint than typical models,” accord-
safe within the space allowed in shipping ing to Liang. “Although we can’t predict
containers is not a trivial task.” what will need to be replaced, by bring-
The researchers have used machine ing all of these technologies together we
learning to analyze a database of steel can create any part needed on the fly, and
casting processes (using liquid metals and we can do it with scrap metal.”
METALCASTING BRIEFS
Managers at Casting Technology Intl. Ltd. – a research foundry affiliated
with the U.K.’s Sheffield University – completed a £2m buyout of the
operation earlier this year. CTI specializes in developing and testing
casting and treatment processes for aerospace and transportation
businesses.
David Loomes, Technical Manager, loads a Class A pump impeller into a
vacuum Heat Treatment Furnace at CTI.
The Non-Ferrous Founders’ Society and THORS eLearning Solutions, a de-
signer of online manufacturing courses, launched the NFFS Academy, an online
e-learning portal developed to provide technical training programs to foundry
employers and workers. The NFFS Academy provides immediate access to
more than 120+ technical courses on manufacturing topics such as Materials,
Engineering Drawings, Quality, Industrial Safety, Industry 4.0, Sales, Manufac-
turing Processes, and Manufactured Products. Visit www.nffs.org/academy.
United Steel Workers members staged a two-week strike at Bradken
Foundry in Atchison, KS, from late March into early April. “We’re excited the
strike is over and looking forward to having everyone return back to work to
get everything back in operation,” according to a statement by Bradken v.p.
- Operations Ken Bean. “From a company standpoint we’re very pleased we
were able to get the changes we needed to be sure Atchison and St. Joseph
remain viable to have success in the future. We were able to come to some
compromises on some things.”
Furnace Charge
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 ^ NEWS MAKERS
New Managing
Director at Kurtz Ersa
Automation
r. Michael Wenzel is the new
D managing director of Kurtz Ersa
Automation GmbH, a developer of au-
tomation and robotics for foundries, elec-
tronics manufacturing, and particle foam
processing.
We n z e l j o i n e d
Kurtz Ersa Corp. six
months ago, initially
in an advisory capac-
ity for the Kurtz Ersa
Automation business
unit. He is described
Wenzel as an expert in “busi-
ness development of
technology companies and an accom-
plished manager for all relevant areas,
such as development, production, sales,
purchasing and service.
“The main task of the new managing
director will be the sustainable growth
of the Kurtz Ersa Automation business
unit,” according to statement.
Wenzel earned a doctorate in physics
from the Julius Maximilian University
of Würzburg in 1992. Over a 30-year ca-
reer he has served as a managing director,
consultant, and interim manager busi-
nesses in mechanical and plant engineer-
ing as well as automation. From 2003
to 2018, Wenzel was a member of the
“Robotics & Automation” board within
the German Mechanical and Plant Engi-
neering Federation (VDMA), and he held
offices such as chairman of the Robotics
Department and chairman of the Robot-
ics & Automation Association.
New Materials Expert
for LIFT
IFT, the Detroit-based and U.S. Dept
L of Defense-supported manufactur-
ing research institute hired Amberlee
Haselhuhn, Ph.D., as senior engineer
for its technology team. Haselhuhn will
lead the institute’s materials and joining
development and evaluation work, tar-
1 2 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
geting new products and manufacturing
processes. She also will work on the In-
tegrated Computational Materials Engi-
neering (ICME)-based design of materi-
als/metal alloys and joining technologies,
to optimize desirable mechanical, ther-
mal, physical and chemical properties.
Haselhuhn holds a Ph.D. in Materials
Science and Engineering from Michigan
Technological Uni-
versity. She recently
served as a senior re-
searcher for General
Motors Co.’s Global
Technical Center.
At GM, Haselhuhn
Haselhuhn led research and de-
velopment related to
the joining of advanced high-strength
steels, aluminum and dissimilar metal
sheet, castings, and extrusions for auto-
motive body light-weighting. She also
developed patentable technological solu-
tions suitable for a manufacturing envi-
ronment.
New MD at Hertwich
Engineering GmbH
erold Keune (Dipl.-Ing.) recently
G joined Hertwich Engineering
GmbH as managing director of the
Austria-based developer and manufac-
turer of aluminum melting and casting
systems. Keune previously managed
sales and operations at KHD, a global
supplier of plants and machinery for
the cement industry. With his 25 years
of experience in mechanical and plant
engineering, Gerold Keune will em-
phasize expanding the technological
leadership of Hertwich Engineering, as
well as on increasing internationaliza-
tion and service activities.
“I am looking forward to provide
even better products and services to
our global customers in future and to
contribute to environmentally friendly,
resource conserving and cost-efficient
solutions with our highly motivated
and experienced team,” Keune said.
^ MEETINGS

CastForge
Rescheduled, Again
he CastForge expo scheduled for
T June 8-10 in Stuttgart, Germany,
has been re-scheduled for June 21-23,
2022. It is the second postponement for
CastForge, which was held for the first
time in 2018 and had been planned for
renewal in June 2020. Travel restrictions
resulting from the Covid-19 pandemic
are the cause of both cancellations.
CastForge 2018 attracted more than
3,700 visitors and over 150 exhibitors. ing prospects for the trade fair industry, The announcement noted that about
The event draws manufacturers of cast- the risks relating to an event in June this 80% of participating exhibitors have
ings and forgings, and specialty proces- year are no longer acceptable for the ma- committed to attend the 2022 event. “A
sors of those products, to exhibit their jority of exhibitors,” according to Mess physical presence is vital for CastForge,”
capabilities to industrial purchasers. At- Stuttgart, the organizer. “However, a stated Gunnar Mey of Messe Stuttgart.
tendees include representatives from me- physical meeting is vital for the industry. “We are therefore continuing the exist-
chanical engineering, plant construction, The exhibitors at CastForge, around 62% ing concept together with the industry
drive engineering, pump and hydraulics of whom travel to Stuttgart from coun- and are taking every step to ensure that
manufacturing, and utility vehicles con- tries outside Germany, therefore jointly the Trade Fair for Castings and Forgings
struction. agreed with Messe Stuttgart to postpone with Processing can be staged safely and
“Due to the continued lack of open- the trade fair by another year.” successfully in 2022.”

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· Combination Wheels
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· Cutoff Wheels
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· Flaring Cupstones
· Plugs & Cones
· Mounted Points
· Carbide Burs
· New Patent Pending Capstone
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M AY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 1 3
^ TECHNICAL DEVELOPMENT

Lowering the Pressure on Diecasting Development

A new research foundry adopts a series of flexible melting and forming capabilities that suggest
a new range of possibilities for low-pressure diecasting.

D
iecasting has earned considerable attention from indus- num but also higher-temperature melting, for example for copper
trial designers in recent years, regarding finished products alloys. This multi-functionality is possible thanks to both direct and
and consequently production systems. This is mainly the indirect induction melting and a “crucible quick-change system.” It
outgrowth of those designers’ can melt standard metals (alu-
efforts to develop lighter ver- minum, copper, brass, bronze,
sions of standard products, in magnesium, or steel) as well as
automotive manufacturing most non-metallics, like salt mixtures.
obviously. Those efforts led to Currently, salts are a medium
the development of structural being studied for “lost core” pro-
castings and drivetrain parts de- cesses using HPDC to develop
signed in aluminum alloys, for hollow castings, like engine and
volume production. High-pres- battery housings. IFAM suggests
sure diecasting is adopted to its new foundry could be a cen-
manufacture parts that might ter for researching salt cores in
A flexible induction
otherwise be produced by sand melting unit for low-pressure diecasting.
casting or investment casting, A new, low-pressure casting machine installed at standard metals and The new foundry’s furnace
non-metallics.
often to be followed by exten- IFAM’s research foundry in Wolfsburg, Germany. is a 110-liter, 130-kW vessel for
sive finish machining and as- melting at up to 1,650 °C, with
sembly. HPDC makes it possible casting pressure up to 1.0 bar.
to produce highly detailed but The 1,310 × 1,290 mm2 lower
lighter engine and drivetrain mounting surface can accommo-
components, lighter structural date molds weighing up to 3,500
parts, and possibly to eliminate kg. The upper mounting surface
some post-production steps. of 1,200 × 1,200 mm2 allows a
The next turn in this tale in- maximum clamping force of 60
volves systems for producing metric tons.
those parts, and the recent emer- A vertically movable furnace
gence of super-sized machines to chamber allows free accessibil-
produce lightweight diecastings ity of the melting crucible -- for
of expanded dimensions. quick alloy changes. In addition
An overview of IFAM’s new research foundry for low-pressure diecasting. in
And both of these ongoing Wolfsburg, Germany. [Photos by Fraunhofer IFAM] to the flexible processing of dif-
trends will leave some asking: ferent melts, the plant can work
What else can diecastings do? Germany’s Fraunhofer Institute for with conventional steel molds, as well as sand or semi-molds.
Manufacturing Technology and Advanced Materials (IFAM) opened Fraunhofer IFAM also has invested in a Kurtz AL 16-12 LPDC
a new research operation in Wolfsburg, Germany, to address that system, to be commissioned later this year.
question, but there the focus is on low-pressure diecasting. The new plant concept was developed in collaboration with
Low-pressure diecasting accounts for a much smaller proportion TEGISA Giessereianlagen und Industrieöfen GmbH, based on a
of all diecasting operations than HPDC. Typically, it is applied for prototype in operation at Fraunhofer IFAM in Bremen since 2015.
alloys with low melting points (e.g., aluminum alloys) and parts Examples of research to be taken up by IFAM include composite
weighing up to 150 kg (about 325 lbs.) The advantages of LPDC are casting for integrating metallic structures and profiles (aluminum or
that it can form very high-strength parts with complex geometries steel) directly into a casting; combining low-pressure diecasting with
and excellent dimensional accuracy. Solid castings with thick walls non-metallic primary or forming processes (e.g., sheet metal forming
are typical applications, such as light-alloy automotive wheels, but or plastic injection molding); or producing cast rotors for electric
also some chassis and drivetrain components and housings. drives – generally a product of high-pressure diecasting.
IFAM’s LPDC foundry is intended to host applied research proj- The capabilities adopted by IFAM indicate a new range of growth
ects, with conventional melting and casting capabilities for alumi- possibilities for LPDC.

1 4 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
Manage your melt differently.
Inductotherm’s iSense™ System brings your equipment together like never
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Important: Appropriate Personal

Protective Equipment (PPE) must
be worn by anyone in proximity
to molten metal.
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Metallurgy

Cupola System Design

Optimizes Melting Operations
A cupola’s thermal efficiency determines how effectively sensible heat is directed to the molten
iron, and how much wasted heat is lost to the furnace, the exhaust gasses, slag, etc.
Maximizing a cupola furnace’s thermal efficiency requires the operator to understand the critical
design details.
Ron Beyerstedt
-- will be discussed in further detail.
Heat energy supplied by coke is dependent
on the amount of coke present. A given coke
rate supplies a finite amount of heat energy.
The cupola’s thermal efficiency determines
how the available heat energy is divided be-
tween sensible heat to the molten iron and
wasted heat to the cupola; exhaust gasses,
slag, etc.
Retained-slag is a liquid and as such it
transfers heat to the cupola shell and refrac-
RYSZARD PARYS | DREAMSTIME

tory much quicker than chunks of coke will

do. The volume of retained-slag inside the
cupola is basically unknown in most cupola
operations. Evidence of liquid slag backing
up and reaching tuyere level is commonplace.

P
revious entries in this series examined the roles iron oxide Typically, the tuyere level is nearly 40 inches above the tap-hole,
and free-oxygen atoms for cupola melting processes. a separation that results in large volumes of unwanted slag present
Both of these are important factors for foundries seeking inside operating cupolas.
to maximize cupola operation. Assuming iron-oxide for-
mation within the cupola has been addressed and countered, the next Regulating hydraulic pressure
step for the operators is to make the changes necessary to maximize The volume of retained-slag inside the cupola is regulated by the
thermal efficiency of the cupola. hydraulic relationship created by the metal dam height versus the
During the cupola’s melt cycle, coke is combusted to produce back-pressure inside the cupola pushing down on the slag layer, and
heat. Maximum heat generation happens in the tuyere raceway, or the weight of slag pushing down on the molten iron reservoir created
slightly above it. Because no oxygen is contained in blast air reaching by the metal dam. The metal dam establishes the iron reservoir that
below tuyere level, no coke combustion occurs there; hence no heat must be pushed out the tap-hole before the lighter slag can escape the
is produced below tuyere level. Therefore, all heat energy below the tap-hole. Restated, the force pushing on the molten metal reservoir
tuyere level must be transferred from the hot zone is the pressure formed inside the cupola from the
of the tuyere raceways. This is the third in a series of re- blast air and the weight of the slag on top of the
Molten iron droplets descending through the ports examining cupola design, molten metal.
hot zone provide the heat-transfer mechanism. cupola melting practice, and Back-pressure within the furnace is not rou-
Heat is robbed from the droplets throughout their cupola technology solutions. tinely measured on any cupola. However, when
descent to the bottom of the cupola, transferring Also see: an extraordinary effort is made to do so, the pres-
heat to the coke and slag found there. Greater dis- “Maximizing Cupola Perfor- sure recorded is vastly different than the operating
tance between tuyere level and the cupola bottom mance,” FM&T March 2021. back-pressure recorded by the instrumentation
causes more coke and slag to be contacted by the “Controlling Conditions for Cu- provided by the cupola’s manufacturer. The nor-
molten droplets. This important cupola design pola Melting,” FM&T April 2021. mal back-pressures indicated include the blast-
detail -- i.e., tuyere elevation above the tap-hole air resistance due to the confined design of the

1 8 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
tuyeres, tuyere pipes, wind box, etc.
The true blast pressure inside the cupola is seldom measured but
end up at a startling 10% of the cupola’s indicated back-pressure.
Cupola operators have been misled for years by the erroneous
pressure readings.
Most cupolas contain “safety tuyeres,” which are drain ports,
whereby blast pressure is sealed off by thin aluminum plates; de-
signed to melt instantly and open to metal flow if liquid iron rises to
the level at which those plates are installed. Typically, safety-tuyeres
are installed approximately 14-17 inches below the water-cooled
tuyere level.
Cupola designs do not allow easy measurement of internal pres-
sure created by blast air. Cupola manufacturers must change that
and incorporate simple pressure ports, which will ensure precise
pressure within the cupola and facilitate accurate adjustment of
metal dam heights.
Optimizing metal flow
One method used to determine internal operating back-pressure is
to install a pressure gauge through the aluminum “burn-out” plate in
the safety-tuyere. A problem encountered on most cupolas with this
technique is the safety-tuyere quickly plugs with slag during melt
start-up, so only a quick glimpse of internal pressure is obtained. But
the back-pressure obtained during bed burn-through, prior to melting,
can be obtained and compared to the “normal” back-pressure read-
ing. Thus, the relationship between actual back-pressure within the
cupola and the cupola’s “normal” back-pressure can be established.
Slag produced during the melt cycle accumulates within the cu-
pola according to the hydraulic relationship; the “metal dam height”
produces roughly five ounces per inch of dam height and is offset by
the internal back-pressure created by blast air and slag weight on the
molten metal.
Heat-energy losses to retained-slag are a major portion of all
thermal losses. Yet, few cupola operations are concerned with high-
retained-slag levels. This must change. Operators’ concern must be
raised, to minimize retained-slag volume inside cupolas.
Actual internal back-pressures indicate 2-8 ounce maximum
pressure exists. More measurements are needed to establish typical
pressures. But five ounces of back-pressure offsets one inch of metal
dam. Most cupolas operate with excessive metal dam heights, pro-
ducing the near-tuyere-level retained-slag conditions that hamper
cupola melting today.
Cupola operators take note: check the height of the metal dam in
Attention Cupola Operators:
• Check the metal dam height
• Check the time for slag to appear after tap-out.
Time measurement is an accurate indicator of
retained-slag level and proper dam height.
• Aim for 7-8 minutes.
M AY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 1 9
your furnace -- and check the time for slag to appear after tap-out.
Time is an accurate indicator of the retained-slag level (aim for 7-8
minutes) and the proper dam height.
Managing slag volumes
After cupola tap-out, molten metal extends back into the cupola
and establishes its height above the tap-hole, in relation to the metal
dam height. The hydraulic balance previously discussed comes into
effect. Slag cannot exit the tap-hole until the hydraulic balance is
overcome.
Following tap-out, slag continues to build up inside the cupola
until all molten iron is forced out of the cupola. At that point, the low-
er-density slag flows out the tap-hole and steady-state retained-slag
levels are achieved.
The time elapsed for slag to flow after tap-out serves as a good
indicator of the retained-slag level inside the cupola, and the need for
reduced metal dam height. Many cupolas do not begin slagging for
an hour or more. Simple calculations will indicate the slag volume
inside the cupola. Cupola operators should realize that slag volume is
robbing heat from melting iron.
Many unwanted slag / metal chemical reactions occur in the re-
tained-slag layer. A large volume of retained-slag promotes long con-
tact time that the molten droplet endures during its downward travel.
Concerning lime removing silicon from molten iron, in one instance
a two-inch reduction in metal dam significantly reduced silicon loss.
Cupolas with proper metal dam height should allow slag to flow
out the tap-hole within 10 minutes.
Retained-slag levels dictate the heat loss / heat robbed from the
metal droplets. The descending molten-metal droplets continuously
heat all slag retained inside the cupola. Minor reductions in the re-
tained-slag level inside cupolas have produced 75°F and more metal
temperature increases. Cupolas operate effectively with 2- to 3-in.
metal dams.
Adjusting cupola pressure
Later this year, Mastermelt will introduce a moveable metal dam
design for cupola front boxes, designed to rise and fall as the inter-
nal back-pressure fluctuates. This device cannot be utilized until
slag chemistry is perfected to eliminate iron oxide. A free flowing,
non-sticky, non-crusty slag must exist so that the moveable dam
refractories can slide on themselves without tearing up the contacting
surfaces. That type of cupola slag is being produced in de-oxidized
cupola operations today, but this is not a well-known process. Still, it
is a critical aspect of the new, moveable metal dam technology.
Slag produced during normal cupola melt cycles results from
melted coke ash/residue, melted adhering sand and dirt, by-products
of oxidation reactions occurring inside the cupola, and melted lime.
Coke ash is primarily silica, SiO2, and it amounts to approximately
8% of the coke weight.
Oxidation by-products contained in the slag are primarily SiO2
and MnO. Many cupolas operate with 35% silicon/manganese oxi-
dation loss. Lime is added to reduce the composite slag chemistry’s
melting temperature. With de-oxidation, less silica is contained
Metallurgy

within the slag, making it possible to reduce the volume of

Cupola Slag Analysis: lime addition. ( See Cupola Slag Analysis. )
• Typical cupola slag @ 30 tph melt rate for one hour Cupola thermal efficiency
• Coke rate = 550 lbs.; Limestone rate 120 lbs.; To review:
• Silicon = 1.70% Si; Manganese = 0.60% MN 1. Coke rate determines heat available for melting and
• SiO2 from coke ash = 550 lbs. x 12 = 6600 lbs. x 8% ash = 530 superheating iron.
lbs. 2. Metal dam height determines volume of slag retained
inside the cupola.
• SiO2 from oxidation = 60,000 x 1.7%Si x 35% = 670 lbs.
3. Determine metal dam height using actual operating
• MnO from oxidation = 60,000 x 0.6%Mn x 35% = 250 lbs. data from the cupola.
• Slag from adhering sand on sprue and dirt = 50 lbs. 4. All material, coke and retained-slag, below tuyere
level is heated by robbing heat from metal droplets.
• Slag from limestone @ 22% of coke = 54 lbs. (120 lbs.
limestone = 54 lbs. lime) 5. Retained-slag should be minimized
6. Mastermelt DeOX Metal Treatment reduces slag pro-
• Slag from coke ash = 530 lbs.
duced during cupola melt cycle by 62% or more.
• Slag from oxidation = 920 lbs. In articles to follow in this series, slag generation in EFs
• Slag from sand and dirt = 50 lbs. and cupolas will be more thoroughly reviewed. Cupola de-
sign factors affecting thermal efficiency will continue to be
• Slag from limestone = 54 lbs.
examined. Tuyere height above the tap-hole, a very critical
• Total slag = 1554 lbs. cupola design parameter, will be thoroughly reviewed.
• Total slag w/o oxidation and reduced limestone = 600 lbs. In the end, an optimum cupola operation and optimum
• With DeOX injection: cupola operating technique will be presented.
Ron Beyerstedt is the president of Mastermelt LLC. Contact
• Slag volume reduction = 62% reduction = 950 lbs. less slag/hr. him at ron@mastermelt.com

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2 0 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
Finishing
Choosing the Right Vacuum
Impregnation Program
A continuous process and a recoverable sealant transformed one manufacturer’s in-house
impregnation operation by reducing costs, increasing quality, and improving efficiency.
Andy Marin
I
n-sourcing vacuum impregnation is a choice that many OEMs
consider, to reduce manufacturing costs for critical components. A
North American motorcycle manufacturer made that choice more
than a decade ago, considering multiple sealant formulae and different
equipment and technologies.
The OEM was sold on equipment that claimed to eliminate waste-
water discharge, seal castings at a better rate, and would require min-
imal adjustments, maintenance, and repair. The equipment they se-
lected used a recycling sealant.
A new challenge. Over time, the motorcycle manufacturer discov-
ered that what it had been sold was different from the reality of what it
had acquired. It found that the recyclable sealant’s chemistry changed
over time, and so did the recovery results. The nature of recyclable
sealant required it to be mixed with water in the impregnation process.
While the sealant was pure at first, it lost its properties once in contact
with water, and never returned to its original formulation.
Also, a wash-water conditioner was needed to maintain the sealant
effectiveness. But, for the sealant to work effectively this conditioner
had to be added daily, and at an exact ratio. If the ratio was not correct,
then the sealant became unstable. The OEM found that excess chemi-
cals carried into the wash and cure modules increased part contamina-
tion and damaged the system.
The system proved to be remarkably expensive, too. The manu-
facturer booked costs totaling more than $1 million due to scrap parts,
M AY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 2 1
Excess sealant chemicals carried into the
wash and cure modules increased part
contamination.
repairs, maintenance, labor, sealant consumables, and sealant support
chemistry. The cost of managing the system exceeded the cost to out-
source the impregnation process.
The realization set in that its vacuum impregnation strategy needed
to change, and the manufacturer had an opportunity to make that
change at the start of a new crankcase program. It designed a new,
lighter crankcase that required 100% of the parts to be sealed. Based
on prior experience and data, the manufacturer determined it had to
overcome three main challenges when selecting a new impregnation
system.
Maintenance cost. The initial impregnation system had a remark-
able rate for component replacement. The manufacturer needed its
new system to be easier system to operate with less maintenance.
Sealant management. The recyclable sealant required excessive
testing and maintenance. The manufacturer needed a sealant that
maintained its original formulation, and that does not require daily
maintenance by multiple departments.
Poor recovery. The system had a fall-out rate of approximately
14% of the castings. Any parts that were not recovered were scrapped,
and the cost of the scrapped castings totaled approximately $967,000.
The manufacturer needed to recover more castings.
The right solution. Godfrey & Wing recommended its Continuous
Flow Impregnation (CFi) system Dry Vacuum & Pressure (DVP)
process and 95-1000AA recoverable sealant. The CFi uses Godfrey &
Finishing
Godfrey & Wing recommended its Continuous Flow Impregnation (CFi)
system to a motorcycle manufacturer’s the manufacturer’s challenges.
Wing’s Dry Vacuum and Pressure (DVP) impregnation process, which
incorporates a fast, deep vacuum to evacuate the air from the porosity.
After moving sealant into the chamber, high-pressure forces the seal-
ant deep into the casting.
The 95-1000AA recoverable sealant remains pure throughout the
entire process. The CFI’s impregnation module is designed to recover
the sealant in its original formulation. Once the part is impregnated,
the part moves to a centrifuge to recover any unused sealant. The
unused sealant is returned to the sealant reservoir for future cycles. By
retaining the pure sealant, the customer can maximize recovery with
no additives, or excessive maintenance.
After impregnation, the part moves to the CFi’s wash and cure
stations. Because there is no excess sealant, the wash-water remains
clean. This makes it possible for the part to be properly washed and
part contamination is eliminated.
The CFi was designed with maintenance and service at top-of-
mind. The internal components are positioned to enable ease of main-
tenance without interrupting production. The maintenance team can
service principal components through the rear access panels. Quick
disconnect fittings are used so that they can be maintained by hand
without the need for specialty tools. Each module has a line-rated
disconnect so that maintenance does not need to power down the entire
system for service.
While the system and sealant seemed to be the right solution, the
manufacturer wanted to learn more about the technology and sealant
more directly – in real time. Godfrey & Wing linked the manufacturer
in contact with a service center that operates a CFi and uses a recover-
able sealant.
The manufacturers’ technicians toured the service center to learn
about the technology, which proved that the process and recoverable
sealant remain reliable and do not require constant maintenance or
user intervention. They were impressed with the CFi’s throughput,
efficiency, and simplicity, and based on this experience, and data pre-
sented, the manufacturer purchased a CFi.
Better results. The CFi was installed, operators and maintenance
teams were trained, and the system processed parts immediately. Since
then, the CFI has been addressing the manufacturer’s three challenges:
Reduced maintenance cost. The plant is expected to save approxi-
mately $35,000 in maintenance and spare parts annually.
2 2 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
The clean wash water allows parts to be cleaned properly -- with no sealant
contamination.
The maintenance team can easily service the Continuous Flow
Impregnation (CFi) system without the need for specialty tools.
Efficient, easy sealant management. The motorcycle manufacturer
no longer needs to purchase wash-water conditioner, and sealant main-
tenance and oversight is significantly reduced. The manufacturer will
save approximately $20,000 per year in sealant costs.
Improved casting recovery. The CFi’s First Time Through (FTT)
rate is 99% – a 14-point increase over the previous recovery rate that
will save approximately $630,000 per year in recovered castings.
In total, the cost savings and improved recovery is expected to save
the manufacturer approximately $685,000 per year, enabling the capi-
tal expense recovery to be less than 24 months. The CFi’s productivity
and ease of maintenance has changed the motorcycle manufacturer’s
impression of vacuum impregnation.
Choosing the right impregnation process and sealant is a critical
aspect of purchasing in-house vacuum impregnation equipment. Once
the decision is made, it cannot be reversed.
By analyzing system data through due diligence, this manufacturer
selected the right equipment and the sealant that suits its needs. The
CFi with recoverable sealant transformed the manufacturer’s impreg-
nation process by reducing costs, increasing quality and improving
efficiency.
Andy Marin is the marketing coordinator for Godfrey & Wing, a devel-
oper of vacuum impregnation technology. Contact him at amarin@
godfreywing.com
^ SUCCESS STORY

The New Age of Vintage Machinery

A control system upgrade has put an automotive supplier’s +30-year-old diecasting unit
at the cutting-edge of digital process control.
At the same time, the system had to be sim-
ple and user-friendly so operators could easily
supervise, monitor, and control the tasks per-
formed by the machine. Ease of use also would
allow new technical personnel to learn how to
operate it quickly.
Two years ago, in May 2019, Italpresse Gauss
supplied a technical proposal and quotation for
an equipment modernization program focused
on installing the IP LV (Light Version) super-
visor control panel system. The IP LV already
had been the focus in more than 40 successful
XSJUDGHSURMHFWVWKRXJKWKLVZRXOGEHLWV¿UVW
deployment in China.
Installed in October 2019, the IP LV at
Ningbo Boli was designed specifically to re-
place older Italpresse control systems like the
One of four Italpresse IP750T high-pressure diecasting machines at Ningbo Boli Automotive Components. System 2000, System 3000, System PC, and
[Italpresse Gauss photo] Digistar. It employs the Gefran display control-
ler, which is compact, fast and easily accessible

V
ery often a machine update has less to do with new equip- for maintenance. The system’s fanless, 15-in. operator panel offers
ment and everything to do with how a specific machine is full touchscreen control and can record, monitor, analyze, and
operated – or how it is controlled. A control system upgrade display injection data in real time – especially convenient for equip-
by diecasting specialist Italpresse Gauss has brought a vintage ment maintenance technicians and machine operators alike.
high-pressure diecasting machine into the digital age for Ningbo IP LV’s fast network connectivity supports remote machine
Boli Automotive Components, a nonferrous foundry in China’s control and operation via VNC. Its Ewon industrial router enables
Zhejiang Province. remote troubleshooting and monitoring by on-site or offsite engi-
Ningbo Boli is a subsidiary of Ningbo Heli Mould Technology neers, and makes the machine Industry 4.0-ready, with comprehen-
Co. Ltd. producing various automotive parts by sand casting, sive data collection and export abilities.
high-pressure diecasting, and gravity casting. It operates 13 Ital- “A big attraction was how short the whole upgrade period would
presse diecasting machines, including four 750-metric ton, IP750T be – Italpresse predicted one week of commissioning and delivery,”
HPDC machines still operating well after more than 30 years. DFFRUGLQJWR/LQ³,QIDFWWKHSURMHFWRQO\WRRN¿YHGD\VDQGFRP-
“Their casting performance remains far better than newer, pared with installing new equipment the cost was far lower.”
cheaper machines with the same closing force,” explained Zhuxi With only the electrical control system upgraded, the mechanical
Lin, project manager at Ningbo Boli. “So, we didn’t want to scrap operation of the IP750T remains unchanged. However, it’s now pos-
the equipment and replace it with domestic machines, new or oth- sible to use the features of the updated control system to optimize the
erwise. Instead, we talked to Italpresse about upgrading the equip- legacy machines’ performance to improve productivity and quality.
ment, especially the control system.” “Italpresse Gauss met every one of our requirements with
3LFNLQJRQH,37WRXSJUDGH¿UVW1LQJER%ROLKDGGHWHU- this EMP, which has proved to be a very cost-effective solu-
mined the project’s priorities. Scrap castings had to be automati- tion,” Lin said. “We are very satisfied with their efforts and with
cally separated from good castings while the new system had to the better performance of the upgraded machine, especially its
support digital data collection, remote access, and injection data new digital capabilities.
analysis. Any solution had to collect, store, and display relevant “The IP LV control system upgrade is a great option for older
process data like the injection curve in real time, while making it machines that are still working well but whose control systems are
possible to remotely access and export data so that managers could obsolete,” Lin concluded – adding that the remain three HPDC ma-
monitor diecasting production easily. chines would be upgraded with the IP LV system, too.

2 4 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
 ^ MESSAGE RECEIVED
Three Questions Shape Every Marketing Plan
Organizations that communicate clearly have a detailed, up-to-the-moment understanding of their challenges
and opportunities, and what needs to change.
Alexandria Trusov
W
hen I do marketing strategy work with companies, two of
the questions I ask are, “What are your Top 3 challenges?”
and “What are your Top 3 opportunities?” As for the chal-
lenges, at least one of the three responses typically is not exactly mar-
keting: It usually involves processes.
At least one, often two of the opportunities is not exactly marketing
either. It’s usually relates to a business’s sales goals. And I’m never
surprised by this.
It’s also why I phrase the
questions without the word
“marketing” as a constriction.
What the non-marketing items
always have in common is com-
munication, i.e., marketing’s pri-
mary function.
A Marketing Department
touches a lot of other depart-
ments: Customer Service, Sales,
IT, Engineering, Product Devel-
opment, Operations, HR, Finance -- just to name a few. Marketing
requires coordination with those other departments, as well as learning
from them, to create communication flows to customers. It could be
said that there are many distinct marketing disciplines -- up to 41 by
some accounts1 -- but no matter how you count them, even when the
platform and specific message may change, every single marketing
discipline communicates content about a service, a product, or a brand.
Most marketing disciplines require input from other departments
to create communication that resonates with customers and prospects.
Using some common marketing disciplines as examples:
• Employer Branding is usually the HR-coordinated outgrowth of an
operational need for talent. (This may be served up with a side of Inter-
nal Communications support from the Marketing Department as well.)
• Digital Marketing, Direct Marketing, Social Media Marketing,
Traditional Marketing and Video Marketing all can be covered by the
“content” umbrella, which starts with knowing your product/service.
You cannot market a product what you do not know, nor if you don’t
know with whom you are communicating. When I develop materials
for any of these marketing applications, my first stops are Customer
Service, Sales, and Engineering (or R&D), to learn what customers
and prospects are asking, what the objections are, and how our product
solves the problem. (Pro tip: Customer Service also is a rich source of
customer-win stories.)
• Product Marketing often means coordinating with Operations and
Engineering (R&D) for the kind of technical information needed for
1. https://blog.hubspot.com/marketing/marketing-types
M AY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 2 5
catalogs or how-to-guides. Marketing’s job, in this case, is to make
the content accessible and give it a branded look.
• SEO Marketing or Voice Marketing might require some support
from the IT team to re-configure servers or input on optimizing your
website for voice search . It also might require a discussion with the
Finance department to structure a reasonable budget for these efforts.
(Or a new category of “spend.”)
• Event Marketing is likely to
be an all-hands-on-deck affair as
content is created by technical
and service staff; Sales staff and
other departments may be part of
the hospitality outreach during the
event, too.
Spoiler alert: For most of the
Gajus | Dreamstime
opportunities or challenges I learn
about the answer is in one of the
disciplines listed above. Even if
all 41 types of marketing are not
B2B-applicable, it’s pretty clear that communication -- knowing
what you are talking about and to whom -- is the basis of all market-
ing, and communication usually is the way to address the challenge
or opportunity.
After discovering more about challenges and opportunities, the
third question I ask is: “What are you willing to change?” It doesn’t
matter what the challenge or opportunity is, if you aren’t willing to
change, you won’t be able to meet it. What it took to get you this far
is what you have been doing; to achieve more, you must be willing
to do something different than you have done before. In other words,
you need to be willing to change. Change what you are communicat-
ing. Change how you are communicating. Change the platform you
are using for communication. Change.
Whether you are building a single marketing touch, a campaign
or a full marketing strategy, it can be kicked off with answering those
three questions:
• What are your Top 3 challenges?
• What are your Top 3 opportunities?
• What are you willing to change?
Your challenges are opportunities to change. Your opportunities
are catalysts for change. And your changes are what keep your brand,
product, or service relevant to your market.
Alexandria Trusov is the Global Marketing Manager at Alpha Resources
and a B2B marketing consultant to manufacturers and other B2B com-
panies. Contact her at atrusov@truinsightsconsulting.com or visit www.
truinsightsconsulting.com.
^ NEW PRODUCTS
… READ MORE is your tip to visit FoundryMag.com/new-products for up-to-date, extensive, informative reporting on new metalcasting technology.

Skid-Mounted
Scrubber System
BIONOMIC INDUSTRIES INC. re-
leased its new ScrubPac custom skid-
mounted scrubber system, a cost-effec-
tive, “packaged” system engineered to
meet customers’ specific requirements
for process emission control. All nec-
Two new units are designed
for intuitive programming essary components — recirculation
so operations that have pumps, pip-
low levels of automation
will be able to activate ing and valve
the cobot within minutes networks,
of installation, with no
specialized training. exchangers,
instrumenta-
tion, controls,
New Cobots Offer Higher Payloads, Speeds and any other
essential
ABB ROBOTICS is expanding its collaborative robot portfolio with the new GoFa™ items needed
and SWIFTI™ cobot families, offering higher payloads and speeds to complement its to satisfy cus-
established YuMi® and single-arm YuMi cobot. These stronger, faster and more capable Cost-effective, “packaged” tomers’ appli-
systems are available
cobots will accelerate ABB’s expansion in collaborative robotics, meeting the growing for batch or continuous cations are in-
demand for automation across multiple industries. operation, semi- or fully cluded in the
automatic operation.
GoFa and SWIFTI are intuitively designed so customers need not rely on in-house system.
programming specialists. This will unlock industries that have low levels of automation, Systems are available for batch or
with customers able to operate their cobot within minutes of installation, straight out of continuous operation, semi- or fully au-
the box, with no specialized training. tomatic operation, along with pre-treat-
“Our new cobot portfolio is the most diverse on the market, offering the potential ment options (high-temperature gas
to transform workplaces and help our customers achieve new levels of operational quenchers, VOC condensers, super
performance and growth,” stated Sami Atiya, president of ABB’s Robotics & Discrete saturators for fine particulate cap-
Automation Business Area. “They are easy to use and configure and backed by our ture), standard or customer-specified
global network of on-call, on-line service experts to ensure that businesses of all sizes instruments, controls and mechanical
and new sectors of the economy, far beyond manufacturing, can embrace robots for the components, local or remote system
first time.” control/monitoring, and special spill
ABB’s cobot portfolio helps existing and new robot users accelerate automation in containment skids and modularized,
line with four trends -- individualized consumers, labor shortages, digitalization, and skid-mounted assemblies for large sys-
uncertainty -- that are transforming business and driving automation into new sectors of tem hard-to-fit spaces.
the economy. The expansion follows the business area’s focus on high-growth segments Factory-assembled, run-tested, and
through portfolio innovation, helping to drive profitable growth. operational when they arrive on site,
GoFa and SWIFTI are engineered to help businesses automate processes to assist the systems require only process and
workers with material handling, machine tending, component assembly, and packaging utility connections and are available
in manufacturing, medical laboratories, logistics hubs and warehouses, workshops, and for gas capacities from 100 through
small production facilities. 150,000 acfm.
Users comfortable with operating a tablet or smartphone will be able to program and Typical applications include VOC
re-program the new cobots with ease, using ABB’s fast set-up tools. scrubbing, nitrogen-oxide, hydro-
“With this expansion, we are making cobots easier to use and deploy, with real-time gen-sulfide and organo-sulfur compound
support to help speed their adoption in businesses that may have not considered their use removal, acid and ammonia scrubbing,
previously,” Atiya said. “Our experience is that the best performing operations harness halogens and amines removal, aerosol
people’s skills, alongside the potential of new technologies.” … READ MORE removal, fume and gas scrubbing, and
mist removal. … READ MORE

2 6 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
Updated Industrial IT
Monitoring Solution
PAESSLER AG introduced new capa-
bilities to its PRTG Network Monitor,
helping manufacturing organizations to
have a holistic view of both operational
technology and traditional IT infrastruc-
ture data insights.
The PRTG Network Monitor sup-
ports common communication standards
within an industrial IT environment. The PRTG Network Monitor takes an holistic approach that combines both operational technology and
This allows PRTG to bring data from the traditional IT infrastructure data insights.
factory floor into the monitoring con-
cept using native sensors for OPC UA, to cover industrial IT monitoring include: • The implementation of the MQTT
MQTT, and Modbus TCP. The result is • The ability to monitor Modbus TCP messaging protocol (including the abil-
a holistic approach to industrial IT mon- devices on the factory floor without the ity to monitor MQTT Broker and MQTT
itoring by combining both operational need for protocol converters; Statistics, and to send out MQTT-based
technology and traditional IT infrastruc- • Support for the commonly used indus- notifications), providing insights into
ture data insights. trial interoperability standard OPC UA; machine-to-machine communication
Innovations within Paessler’s PRTG • The ability to monitor the health status within the IoT and industrial IT space.
monitoring solution to broaden its scope of Soffico Orchestra; … READ MORE

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M AY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 2 7
 PROUDLY
PRODUCED BY

2 8 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
 A U TO MATED FOUNDRY SYST E M S
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . 260-749-7740
CO N VEY OR S, BELT
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . .260-749-7740
CO N VEY OR S, P NEUMAT I C
Dynamic Air Inc., St. Paul, MN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651-484-2900
CO N VEY OR S, V IBR ATIN G
Conveyor Dynamics Corp., St. Peters, MO. . . . . . . . . . . . . . . . . . . . .636-279-1111
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . .815-455-3222
CO REMAK ING
D RO SS R EC LAMATION
Didion International, Inc., St. Peters, MO . . . . . . . . . . . . . . . . . . . . .636-278-8700
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . .815-455-3222
EL EVATOR BUCK ETS, S E L F CL E ANI NG
States Engineering Inc., Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . .260-747-6195
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . .260-749-7740
F O UN D RY S YS T E M S
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . 260-749-7740
M AY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 2 9
MAT E RIA L H A ND L ING E Q U IPME NT
Conveyor Dynamics Corp., St. Peters, MO. . . . . . . . . . . . . . . . . . . . . . . 636-279-1111
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
MO LD H A ND LING E Q U IPME NT
States Engineering, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260-747-6195
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . 260-749-7740
SA ND H A ND LING E Q U IPME NT
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
States Engineering, Inc., Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . . . 260-747-6195
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . 260-749-7740
SA ND RE CL A MAT IO N E Q U IPME NT
Didion International, Inc., St. Peters, MO . . . . . . . . . . . . . . . . . . . . . . . 636-278-8700
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
SH A KE O U T S, RO TA RY
Didion International, Inc., St. Peters, MO . . . . . . . . . . . . . . . . . . . . . . . 636-278-8700
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
SH A KE O U T S, VIB RAT ING
Conveyor Dynamics Corp., St. Peters, MO. . . . . . . . . . . . . . . . . . . . . . . 636-279-1111
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
VA CU U M CL E A NING E Q U IPME NT & RE NTA L
DeMarco Industrial Vacuum Corp., Crystal Lake, IL. . . . . . . . . . . . . . . 815-344-2222
Visit our website: DeMarcoVacuums.com • Email: Sales@DeMarcoVacuums.com
VA LVE S, B U T T E RFLY
Posi-flate, St. Paul, MN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651-484-5800
ADVERTISE IN THE
PRODUCT EXPRESS
CONTACT:
JOE
DINARDO
440.487.8001
jdinardo@endeavorb2b.com
^ AD INDEX
Advertise Website Page
ASK Chemicals ............................................................www.ask-chemicals.com ..............................................................................IFC-1
B&L Information Systems ................................................www.BLInfo.com ............................................................................................7
Blast Cleaning Technologies (Div of Metcast) ...... www.metcastservice.com ..................................................................................23
Conveyor Dynamics Corp. ............................... www.conveyordynamicscorp.com ..........................................................................11
Cor-Met, Inc........................................................................www.cor-met.com.........................................................................................12
DIDION International, Inc. ................................................www.didion.com .................................................................................... 16-17
Flexovit USA ...............................................................www.flexovitabrasives.com.................................................................................13
Foundry Educational Foundation ....................................www.fefinc.org ............................................................................................30
Foundry Solutions & Design, LLC ............................... www.foundrysd.com .....................................................................................BC
General Kinematics Corp. .....................................www.generalkinematics.com .................................................................................5
Green Sand Controls, LLC .....................................www.greensandcontrols.com.............................................................................IBC
Heraeus Electro-Nite Co. .................................................www.heraeus.com ..........................................................................................9
Inductotherm Corp. ................................................... www.inductotherm.com ...................................................................................15
OTP Industries.........................................................www.omegatractorparts.com...............................................................................20
Roberts Sinto Corp. ............................................................ www.sinto.com ...........................................................................................27
Summit Foundry Systems, Inc. ....................... www.summitfoundrysystems.com ............................................................................3
Webb-Stiles Co.............................................................. www.webb-stiles.com .......................................................................................8

3 0 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
^
BUSINESS STAFF ^
CLOSING COMMENT

continued from p. 28
MANAGEMENT & TECHNOLOGY
2 Summit Park, Suite 300 • Independence, OH 44131
Telephone: 234-466-0200

BUSINESS STAFF
John DiPaola • VP and Group Publisher

DELOITTE
jdipaola@endeavorb2b.com (440) 331-6099
Joe DiNardo • Associate Publisher
jdinardo@endeavorb2b.com (440) 487-8001 “To what extent is your company making use of the opportunity to analyze
machine data, for example to avoid defects in the production process?”
Brenda Wiley • Production Manager
bwiley@endeavorb2b.com (714) 406-2661
Frank Chloupek • Director, User Marketing mistakes is trying to get everything done at once. Management
fchloupek@endeavorb2b.com (909) 736-0826 underestimates the level of impact that changes in one part of the
Robin Slanie • Sales Support Specialist organization can have on other departments. Changing everything
rslanie@endeavorb2b.com
at once, especially for highly interconnected systems, can cause
Steven Porter • Group Digital Advertising Manager
a lot of disruption and delays and can overwhelm plant workers.
sporter@endeavorb2b.com
Digital transformation is a process that can continue for sev-
REPRINTS, CUSTOMER SERVICE, AND CONTENT REUSE eral years and should be treated that way.
Reprints/Permissions • Reprints@endeavorb2b.com Managing and securing data. Organizations that use old
SALES OFFICES legacy systems and do not run on modern software solutions
Joe DiNardo • U.S. and Canada
struggle to fully utilize all of the data that becomes available
jdinardo@endeavorb2b.com, Tel.: (440) 487-8001 when they go through digital transformation. Real-time asset
Julian Maddocks-Born, • U.K., Europe monitoring, predictive maintenance algorithms, CMMS logs,
julian@itsluk.com, Tel.: 44-1442-288299
machine performance data -- the amount of data that opens
Yoshinori Ikeda • Japan up through IoT technology and digital transformation can be
Tel.: 81-3-3661-6138, Fax: 381-3-3661-6139
overwhelming. Suddenly, plant managers do not only need data
Cesare Casiraghi • Italy
c.casiraghi@tin.it • Tel.: 39-031-261407 • Fax: 39-031-261380 analysts, but they need to expand their IT department to keep
Adonis Mak • China, Hong Kong everything running smoothly.
adonism@actintl.com.hk • Tel.: +85-2-2838-6298 One Deloitte Industry 4.0 study asked manufacturing com-
Charles Yang • Taiwan panies to what extent they are making use of the opportunity to
medianet@ms13.hinet.net • Tel.: +886-4-2322-3633 • Fax: +886-4-3233-3646
analyze machine data, for example, to avoid defects in the pro-
ENDEAVOR BUSINESS MEDIA duction process. As the chart shows, only a few organizations
Chris Ferrell • CEO
are fully utilizing the data that is available to them.
Scott Bieda • CRO
As digitalization moves forward, it would be surprising to
Patrick Rain • COO
see more and more software platforms on the market that can
June Griffin • CMO
integrate with different apps and sensors and serve as central-
Angela Mitchell • VP, Accounting
ized platforms for all plant data -- as CMMS already does for all
Jessica Klug • VP, Finance
maintenance data.
Mike Christian • EVP, Industrial
Securing the data is almost as great a challenge as managing it.
Monique Leija • VP, Digital Business Development
The more industrial business processes rely on data, automation,
Kristine Russell • EVP, Special Projects
and software, the more are they exposed to cybersecurity threats.
Curt Pordes • VP, Production Operations
One way to combat that threat is by running everything
Glenn Scheithauer • VP, Technology
through internal company servers. However, a much simpler
Tracy Kane • Chief Administrative and Legal Officer
and cheaper approach is to work with reliable software vendors
to make the most out of the cloud-based technology. The final
decision should be based on a case-to-case basis after running a
cost risk analysis.
Endeavor Business Media, 331 54th Ave N., Nashville, TN 37209, U.S.
www.endeavorbusinessmedia.com. Bryan Christiansen is the founder and CEO of Limble
Printed in U.S.A. • Copyright © 2021 Endeavor Business Media, LLC
CMMS. Limble is a modern, easy to use mobile CMMS
All Rights Reserved
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the Engineering Index generally available in libraries. Copying: Permission is registered with the Copyright
Clearance Center Inc. to photocopy any article, with the exception of those for which separate ownership is maintenance by helping managers organize, automate,
indicated on the first page of the article, for a base fee of $1.25 per CCC. (Code No. 0360-8999/97 $1.25 + $.60)
and streamline their maintenance operations.

M AY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 3 1
^ CLOSING COMMENT

Anticipating the Challenges

of Digital Transformation
Automation, robotics, sensors, and different software solutions have completely changed how
people interact with equipment, and how products are created. Manufacturers face a double-
edged sword of risk and reward.

T
he digitalization of business processes is driving the which may have been established for decades now.
competition in manufacturing markets, and this is no- We have seen this first-hand in manufacturing maintenance
where more obvious than on the plant floor. Automa- departments. One organization implemented condition monitor-
tion, robotics, sensors, and different software solutions have ing technology to measure asset health and develop better digital
completely changed how people interact with equipment and maintenance calendars. However, for a few different reasons the
how components and products technicians and mechanics never
are created. Manufacturers with fully adopted the tools. The bot-
high operational costs have a tom line is that the organization
significant incentives to pursue invested capital to acquire tech-
digital transformation. nology they barely used.
However, once that decision To ensure that does not hap-
has been made those manu- pen, top managers must involve
facturers are faced with a dou- all employees in the digital trans-
ble-edged sword of risk and formation process, explain what
reward. While automation and is being done and why, and show
digitalization promise a high how these steps will benefit them
NASIMI BABAEV | DREAMSTIME

return on investment, the tran- as workers and the organization

sition process comes with big
upfront costs and nobody can
guarantee a smooth ride.
Here are a few sinkholes
they will need to avoid in order
to maximize the chances for successful digital transformation.
Getting the necessary buy-ins. Ensuring the necessary buy-in
comes in two parts: budget approval and change management.
This is a situation where the organization’s top managers
must be all-in. There are going to be upfront costs, there are
going to be ongoing implementation costs, there is going to
be some decrease in output while the changes are rolling in,
and there are almost certainly going to be some unforeseen
expenses. Top managers need to realize all of that, allocate the
necessary budget, and show the commitment to pursue this proj-
ect up to its completion.
The second part is getting buy-in from all other employees.
This is often discussed under the term “change management”
and it is a challenge for any organization that undertakes digital
transformation. Industrial organizations might have additional
struggles in this regard, as they will have to replace long-stand-
ing legacy systems and push workers to change their workflow,
as a whole. The right people must
be given the right responsibilities
-- and even offered incentives for
jobs well done.
Setting the right goals, strat-
egy, and pace. The technology itself should not be a driver of
change; that’s what the goals are for. In other words, you are
not implementing new tools simply because there are new tools
available in the market. You are implementing them because
you are trying to reach particular goals.
There are many different things that an industrial organi-
zation can aim to digitalize and automate. The success of the
implementation will depend on how well the organization estab-
lishes a realistic plan of action.
First, you look at the goals. By knowing what you are trying
to achieve (and the budget you have at your disposal), it is going
to be much easier to select which business processes need to be
transformed and what kind of technology needs to be imple-
mented.
After that list is ready, the strategy must outline the priority
of changes. In the industrial environment, one of the common
continued on p. 31

Bryan Christiansen | CMMS Developer and CEO

3 2 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | M AY 2 0 2 1
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e-mail: engineering@foundrysd.com, www.foundrysd.com