Buyers offer tips to casters.

The July/August Enigineered Casting Solutions editorial asked buyers for advice to metalcasters. Here are some of their answers.

I liked the editorial about communication between casting users and suppliers. It started me thinking about communications in general, and I listed some items that are important from my standpoint as a purchaser. These are basic points in communication, but you would be surprised how often they're overlooked. They aren't related directly to casting design--that's another list I'm working on.

1. Don't be a stranger. Some metalcasting facilities that are within a few hundred miles of my plant are the ones that I never see or hear from. Facilities that are on a different continent visit on a regular basis. Is my business more important to them?

2. Don't just show up. Give a bit of advance notice before you come to see me. Schedule visits regularly so I can set aside the proper amount of time to discuss the issues at hand. We're both busy; let's use our time together efficiently.

3. Look me in the eye. Don't forget the importance of face-to-face communication. Come and visit me; tell me about your latest improvement efforts and new equipment or processes. I'll show you some of the issues I'm working on and maybe ask for your input. We can build a better relationship that way.

4. Use technology effectively. With the amount of technology available to us, we should have no problem getting our points across to the other party. 3-D models, on-line conferences, etc., all help communication and shorten lead times.

5. A picture is worth a thousand words. Everyone seems to have access to a digital camera, and using it to take photos of problems or discussion topics and then emailing them to me helps move things along. Take lots of photos and cull out the ones that aren't crisp and clear.

6. A digital video is worth a billion words. Don't underestimate the power of using short videos to get your point across, specifically when trying to illustrate a metalcasting or machining process that could be hard to explain.

7. Let's stay on schedule. When we are collaborating on a project, let's develop a timeline that we both can agree on. Make sure that you and I both stay on track--if I get behind, be sure to let me know I'm late. I'll do the same for you.

8. Keep me up to date. Lots of companies have newsletters. Email them to me or put me on the mailing list. These help me keep up with changes at your metalcasting facility.

Anonymous

I worked in a metalcasting facility until 1999, when I transferred to purchasing castings for Detroit area designers. Having seen both sides of the industry, I enjoyed your article, "Facilitating Effective Communication," in the July/August issue of ECS.

The major problem I see with U.S. metalcasters is a lack of honest communication. As a casting buyer, I find their "take it or leave it" attitude to be the most difficult thing to deal with. After that is the excessive time taken to respond to RFQs and other questions and very poor corrective actions to most metalcasting associated defects.

Other aspects that create trouble are the U.S. facilities not willing to strive for quality. I receive numerous responses to complaints that sound like: "I can only correct defects above 2%, as the metalcasting industry is an imperfect world."

My supply chain and I were discussing a long term supply agreement; one of my requirements was the metalcasting facility embrace the "zero PPM" concept. I do understand that this is difficult, but to answer that the supplier was imperfect was appalling to me as a former metalcaster and current casting buyer. When we held defect corrective action discussions, the main answer was, it takes too much time to investigate defect rates, and I do not have time.

It appears the support teams for casting suppliers do not or cannot offer any technical improvements in sand control, consistency of melting, improved molding to reduce grinding, alloy additions or other critical aspects of the operation to assist in defect reduction. This hurts the U.S. metalcasting industry by forcing cost reductions, generally by reducing manpower.

Rex Harrison 

Vibracoustic, N.A.

Plymounth, Mich.

I read your article in ECS ("Facilitating Effective Communication") and appreciate what you're trying to do. We manufacture (machine, assemble and test) 2- to 24-in. aluminum, ductile iron and stainless steel butterfly valves in the U.S. We have multiple problems with most North American--and many Asian--metalcasters. (Although, pricing from Asia helps offset the problems, which are the same between the two continents.)

The following are the areas where we think there needs to be improvement:

* surface finish;

* surface treatment capabilities (plate, powder coat, rust inhibitor);

* cleaning on all parts;

* on-time delivery;

* porosity (usually found after machining is complete);

* lead times;

* pro-activeness and customer service;

* stable pricing;

* process control and consistency of quality.

Just some of the issues we see day in and day out with all of our global casters.

Greg Sisk

Sure Seal Inc.

Mineral Point, Mo.