Crane Washington: A Model For Metal Casting

摘要

This paper describes activities that occurred over a six-year period at the Crane Valves foundry in Washington, Iowa. The authors believe that the methodology used to achieve energy savings and operating efficiencies can serve as a model for the metal casting industry. Achievements of this study have their roots in the company's commitment to grow its foundry operations despite strong foreign competition. Reducing manufacturing costs while retaining product quality emerged as the key to achieving this goal. In this context Crane-Washington agreed to participate in the first Total Assessment Audit (TAA) performed in the nation. The TAA (1992-93) identified capital and non-capital improvement initiatives, as well as the springboard for the Process Method Management (PM~2) Demonstration Project (1993-95); and three year follow up. TAA findings indicated that the PM~2 process of improving operations at Crane-Washington focus on a total quality management program to minimize internal scrap rates and associated costs. The PM~2 model for improving foundry efficiencies was integral to the firm's organizational structure and job responsibilities; work instruction and employee training; quality audit and testing procedures; raw materials specifications; and equipment maintenance specifications. The success of a system like PM~2 is the seeking out and gaining control of the variables that impact the basic operations of melting, molding, core making, and finishing.