Implementation of Metal Casting Best Practices - EERE - U.S. ...

motor, with an older piece of equipment or with a new more efficient version. They can then
present their quantitative findings to facility management for a final decision.
3. Conclusion
Steel Foundry-2 was considered by the assessment team to be the most proactive plant
participating in this project. Foundry management paid close attention to details and had
programs implemented for activities such as compressed air leak repair and high-efficiency
lighting installation while maintaining a clean facility to minimize scrap and provide for a safe
work place. The research implemented by Steel Foundry-2 has greatly improved its bottom line.
The use of shroud pouring has reduced the facility’s cost by approximately 14.5%. Incorporating
the rules and techniques developed by the University of Iowa into the modeling software has
improved the facility’s yield rate by 8%. This is significant savings, especially in light of the
total cost of foundry scrap and the effect of casting yield on profits.
Finally, the plant also retroactively reviewed its workflow and, with the assistance from Iowa
State University, made changes so its process was more predictable and efficient with lesser
chance of mistakes to occur. Steel Foundry-2 is a market leader in the steel casting industry, and
it is because of its proactive measures, that it is able to maintain a competitive edge in the world
market.
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