Shopping for innovation: product innovations case studies show how metalcasting plants have saved money, increased productivity or improved quality with new equipment.

Purchasing equipment is not always as simple as replacing what is broken with a newer model. Many times, a better alternative exists that you have to go out and find. Other times, replacing still-functional equipment with new technology turns out to save your facility bundles.

Brian Gerstmeier, operations manager at AFW Foundry, Lannon, Wis., said the first step in updating the facility is to decide whether it is more economically feasible to repair equipment or replace it. Once you decide to replace, you spend time gathering information on equipment and contacting the manufacturers.

But knowing when and what to buy takes more effort than keeping a list of inventory and reading product literature that comes drifting by your desk. You have to understand the value of each operation in your facility and the money you are willing to spend to fine-tune each of them. You have to be aware of what works and what doesn't with your existing operation in Order to determine what you're looking for in equipment and products. And you have to keep your eye out for new technology that you may not have been seeking but will improve your bottom line substantially.

Dotson Iron Castings, Mankato, Minn., follows a five-step decision-making process on capital improvement projects that exceed $10,000. These steps--description of the "problem", evaluation of the solutions, justification of the solution, payback determination, and recommendation--help the company narrow down its options to find the most suitable solution.

"The key point for us is involvement," said Jed Falgren, vice president of manufacturing. "The most significant benefit is the input we receive from employees that are directly involved in the work."

After the installation, the project team will review how the actual results compared to expectation and determine what changes need to be considered in the next project.

When it's time to purchase new equipment, Dick McMinn, president of Buck Co., Quarryville, Pa., relies on the relationships he's built with his suppliers. "Fewer options are available to muddle through because only a handful of suppliers exist for each piece of equipment in the metalcasting industry," he said. "One of the biggest keys in purchasing is the relationships we've made."

Gerstmeier used the CastExpo '05 in St. Louis to build relationships with equipment manufacturers. It gave him the chance to shop around and meet with prospective suppliers in one short week. He also benefited from the surprise bonus of free advice from other customers.

"I got a lot of outside help from other people in the booth who volunteered their own experiences with certain pieces of equipment," Gerstmeier said. "The foundry show really sealed the deal."

As Gerstmeier learned at CastExpo, sometimes the best way to tell how well something new will work is to wait to see how it worked for someone else. The Product Innovations case studies published every month in MODERN CASTING show how real metalcasting facilities benefited from improvements to their operation. It's a useful tool to help you make that final decision for your own facility.

Following are Product Innovations case studies in which different metalcasting facilities' investments in equipment or technology resulted in saved money, increased productivity or improved quality.

A MODERN CASTING Staff Report