Problem: A manufacturer of truck components presented Carson Castings with a troublesome package of existing castings. Their existing supplier, while price competitive, was experiencing double digit internal and external scrap return rates.

The ancillary costs of the scrap castings were adding up in lost machine time and increased personal costs. The customer was looking to resource the work at a comparably priced ductile foundry, but with the expectation of a much lower scrap return rate.

Solution: Carson Castings travelled to the existing foundry source to view the pattern equipment used by the customer. During discussions it was determined that the castings were dimensionally too big to run on the existing equipment they were tooled for. Using the existing equipment was not an option - the castings needed to be tooled on new equipment.

After replacing the tooling, Carson Castings was able to place the work at a ductile foundry with a comparable piece price to the old source and significantly reduce the scrap rate.