Ductile and Gray Iron Foundry Commited to Continuous Customer - - PowerPoint PPT Presentation

ductile and gray iron foundry
SMART_READER_LITE
LIVE PREVIEW

Ductile and Gray Iron Foundry Commited to Continuous Customer - - PowerPoint PPT Presentation

Ductile and Gray Iron Foundry Commited to Continuous Customer Satisfaction Our Company: Metalfit was established in Monterrey, Mexico in 1990 as a manufacturer of flanged pipe fittings for distribution to both the U.S. and Canadian


slide-1
SLIDE 1

Ductile and Gray Iron Foundry

“Commited to Continuous Customer Satisfaction”

slide-2
SLIDE 2

Our Company:

Metalfit was established in Monterrey, Mexico in 1990 as a manufacturer of flanged pipe fittings for distribution to both the U.S. and Canadian markets. Much of the original tooling was purchased from Kuhn's, Inc. in Dayton, OH. Initially the company relied

  • n
  • utside

foundries to supply its casting

  • requirements. It soon became apparent however that in order to offer the high

level of service Metalfit wanted to achieve we would need our own foundry. Since the principals of Metalfit all had strong foundry backgrounds it only made sense to vertically integrate into the foundry business. In 1995 we purchased a small cupola gray iron foundry in a suburb of Monterrey which is Pesqueria. The site is now approximately 9.2 Acres and has been under constant growth and development since our acquisition. We produced our first induction melt ductile iron in April of 1996. In January of 2000 Griffin Pipe Products acquired Metalfit and subsequently invested an addition $3MM in P&E over the next three years. After 3 years and several top management changes Griffin decided to discontinue it's participation in the fittings market with the exception of their large diameter proprietary fittings which Metalfit still produces today. The original owners of the company were

  • ffered the opportunity to buy the business back as Griffin realized its potential

strategic value to a competitor. The company currently has approximately has 160,000 square feet under roof and 195 employees.

slide-3
SLIDE 3

Markets & Products

Waterworks Residential & Commercial Water

slide-4
SLIDE 4

Markets & Products

Industrial Agricultural

slide-5
SLIDE 5

Products (Alloys & Sizes)

  • Gray Iron ASTM A48 – Class 20, 30 and 40
  • Gray Iron ASTM A126 – Class A, B, C
  • Ductile Iron ASTM A536 – Grades 65-45-12, 70-50-05, 80-55-06
  • Capability of Pouring:
  • Min. 5 lbs Max. 2.5 Tons
slide-6
SLIDE 6

Customers

slide-7
SLIDE 7

Location:

Property: 9.2 Acres Under Roof: 160,000 Sq. Feet Address: Carretera a Pesquería Km. 3, Pesquería N. L. México

slide-8
SLIDE 8

Production Capabilities:

  • Tooling Production
  • Tooling Storage
  • Induction Melting
  • Green Sand Molding
  • No-Bake Molding
  • Floor Molding
  • Coremaking
  • Cleaning and Grinding
  • Machining (Conventional Equipment)
  • CNC Machining
  • Hydrostatic Testing
  • Painting and Lining
slide-9
SLIDE 9

Tooling Production:

Complete patternshop for the production

  • f

traditional manual pattern making, as well as with state

  • f the art computer assisted design

and tooling manufacture with CNC equipment. Materials for tooling available in wood, resin, and aluminum

slide-10
SLIDE 10

Tooling Storage:

In our 37,000 square feet tooling warehouse we store around 3,000 different patterns and core boxes

slide-11
SLIDE 11

Induction Melting:

Inductotherm Furnace Dual Track 1,250 KW Inductotherm Furnace Power Track 1,250 KW Combined Melting Capacity: 4.2 Tons/hr.

slide-12
SLIDE 12

Green Sand Molding:

  • Semiautomated molding line flask size

30” x 30” – 12”/12” for castings from 5 to 150 pounds.

  • Semiautomated molding line flask size

42”x44” – 16”/16” for castings from 150 to 300 pounds.

slide-13
SLIDE 13

No Bake Molding:

Semiautomated flaskless molding

  • line. Molds up to 64”x64” – 24”/24”

for castings from 300 to 1,000 pounds

slide-14
SLIDE 14

Floor Molding:

Floor Molding Flasks up to a maximum of 110”x110” – 45”/45” for castings from 1,000 to 5,000 pounds

slide-15
SLIDE 15

Coremaking:

Shell and No-Bake Coremaking

slide-16
SLIDE 16

Cleaning and grinding:

1 Wheelabrator Turntable Blast Machine 2 Pangborn Tumbleblast Machines

slide-17
SLIDE 17

Machining (Conventional Equipment)

13 Conventional Machine Tools: 1 Horizontal Boring Mill 1 Horizontal Lathe 3 Vertical Lathes 2 Boreface Machines, 4 Multiple Spindle Drills 2 Radial Arm Drills

slide-18
SLIDE 18

CNC Machining:

7 CNC Machines: 1 Horizontal Lathe 2 Vertical Turret Lathes 2 Vertical Machining Centers 2 Horizontal Machining Centers

slide-19
SLIDE 19

Hydrostatic testing:

Hydrostatic testing for parts that service under pressure.

slide-20
SLIDE 20

Painting and Lining:

Coatings and linings applied by brushing, spraying or dipping.

slide-21
SLIDE 21

Quality Control:

Our Quality Control System provides the framework to ensure quality throughout our process. Our laboratory is fully equipped for:

  • Sand testing
  • Chemical analysis (Spectrometer and Leco)
  • Mechanical testing (Universal Machine, Brinnell hardness)
  • Metalographic Analysis
  • Ultrasonic Testing
  • Dimensional Lay-out and Inspection

We will be certified ISO-9001:2008 by the end of 2011.

slide-22
SLIDE 22

Quality Control:

We offer 100% traceability of our products

slide-23
SLIDE 23

Storage of Finished Product:

Inventory

  • f

finished product to provide the best possible service to our customers

slide-24
SLIDE 24

List of Equipment:

Qty Description

TOOLING PRODUCTION 1 Quintax CNC Router 5-axis with computer assisted design capabilities. MELTING 2 Inductotherm Melting Units, 1250 Kw, with 2 Coreless Furnaces 1.5 Ton ea. GREEN SAND PREPARATION 1 Beardsley & Piper 85-B Speed-muller, 3000 Lb. batch. 1 National Engineering Mulller 2 ½ F, 2600 Lb. batch. 1 Full Installation for handling, storage and preparation of the returned sand. GREEN SAND MOLDING 1 Semi-automatic Cope and Drag Molding Line, flask size 30"X30"- 12"/12“ with International PVKL jolt-squeeze molding machines and complete mold handling system. 1 Semi-automatic Cope and Drag Molding Line, flask size 42"X44"- 16"/16“ with International PVKL jolt-squeeze molding machines and complete mold handling system. NO-BAKE SAND PREPARATION 1 Palmer Mechanical Sand Reclaimer, 10 Tons/hour 1 Gudgeon Thermal Reclaimer, 1 Ton/hour NO-BAKE MOLDING LINE 1 Palmer Continuous mixer M1000XL, 1000 pounds per min 1 Semiautomatic Molding Line with vibration table, mold handler, rollover, belt conveyor and hydraulic mold pushers. 3 5 Tons Overhead Bridge Cranes NO-BAKE FLOOR MOLDING LINE 1 Palmer Continuous mixer M1000XL, 1000 pounds per min 3 15 Ton Overhead Bridge Cranes COREMAKING 1 Shalco U-360 Shell-Core Machine, 200 pound max core 1 B&P Cormatic SF-10A Shell-Core Machine, 100 pound 1 Carver Continuous mixer, 300 pounds per min - No Bake sand 1 Dependable Continuous mixer, 500 pound per min - No Bake sand CLEANING & GRINDING 2 Pangborn 34N Rotoblast machines, 34 cubic foot capacity. 1 Wheelabrator shot blast machine. Swing Table type, 96” Table 3 Hermann Williams Bottom-up drills.

slide-25
SLIDE 25

List of Equipment:

Qty Description

MACHINING-CONVENTIONAL EQUIPMENT 1 Union BTF 110 Horizontal Boring Mill, 5" Spindle with CNC Control 1 Bullard Cut Master M-75 Vertical Boring Mill Table 66" Swing 78" 1 Gidding & Lewis 64-VBM Vertical Boring Mill Table 62", Swing 64" 1 King Vertical Boring Mill, Table 42", Swing 46" 1 Monarch Horizontal Engine Lathe, Swing 26" 1 Natco B20B Two Way Head Borefacing machine 1 Natco B20B Three Way Head Borefacing machine 1 Natco Multiple Spindle Drill Press B3A - 12 Spindle, 1.5" Upper 2 Natco Multiple Spindle Drill Press D4B - 16 Spindle, 2" Upper 1 Natco Multiple Spindle Drill Press G4E - 36 Spindle, 1.5 Upper 1 Carlton Radial Arm Drill 15" Col, 5 Feet Arm 1 Carlton Radial Arm Drill, 9" Col, 4 Ft Arm CNC MACHINING 1 Toyoda FH-100 CNC Horizontal Machining Center 1 Mori-Seiki MH 63 CNC Horizontal Machining Center 1 Monarch VMC 45 CNC Vertical Machining Center 1 Mori-Seiki MV 65 CNC Vertical Machining Center 1 Olympia V-40 CNC Vertical Turret Lathe, Table 46", Swing 57" 1 Gidding & Lewis 60VTL CNC Vertical Turret Lathe, Table 60", Swing 70" 1 Mori-Seiki SL-7 "Slant Bed" CNC Lathe, Swing 24" PAINTING 1 Chain conveyor for dip painting. 1 Booth for spray painting. LABORATORY 1 Complete sand control equipment: moisture teller, permeameter, sand strength tester, methylene blue, grain fines rotap, shell and pep-set strength testers 1 Spectrometer Spectro-cast for 18 elements. 1 Leco Carbon Determinator 1 Ledds & Northtrup Quick-lab for carbon/silicon indicator. 1 Unitron Microscope for metalographic analysis. 2 Brinnel hardness testers. 1 Ultrasonic Tester for nodularity and wall thickness. 1 Tensile Test Machine Tinus Olsen, 30 T

slide-26
SLIDE 26

Profile of the ow ners:

Manuel Ruiz: President Mark Meyer : Vice President Bruce Eilenberger: Director Ted Muntz: Director

Mechanical Engineering Monterrey Institute of Technology

MS Metallurgy National University of Mexico

MBA Monterrey Institute of Technology

Industrial Engineer, Fundidora Monterrey

Production Control, Fundiciones Ruiz (Fittings Foundry)

Plant Manager, Fundiciones Ruiz

President, Fundiciones Ruiz

General Motors Institute

BS Mechanical Engineering/Metallurgy

MS Mechanical Engineering/Metallurgy

MBA Northeastern University

Research Engineer, General Motors

Superintendent of Production General Motors

Foundry Manager, Ward Manufacturing

President, Ward Manufacturing

President, Tokheim, Inc. NYSE

Corporate turn-around consultant, various assignments

Regis University

George Mason University

2 years Active Duty U.S. Army.

Regional Manager Gustin Bacon Div. of Aeroquip Corp.

Regional Manager ITT Grinnell

National Sales Manager Ward Manufacturing

Chief Marketing Officer Ward Manufacturing

President Ward Manufacturing

B.A. University of Iowa

Territory Manager A.Y. McDonald Mfg. CO.

National Sales Manager Pump Div. A.Y. McDonald Mfg. Co.

National Sales Manager Manuf. Div. A.Y. McDonald Mfg.Co.

President – Fab Pipe Inc.

Standards Council Chair for National Association of Pipe Fabricators

Past President – National Association of Pipe Fabricators

ANSI/AWWA A21 Committee Member

35 Years Concentrated Waterworks Industry Experience