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Oberdorfer Aluminum Foundry
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April 2009
Oberdorfer Aluminum Foundries – Improved Rock Shell Process
Oberdorfer LLC, an aluminum foundry in Syracuse, New York has improved its Rock Shell Process. This highly engineered trademark process utilizes green technology as well as lean practices to improve production of its aluminum castings for the general aviation industries.
The recent Rock Shell Process kaizen event has increased flexibility and capacity while reducing floor space and labor by using a one piece flow concept for its sand cores. This continuous improvement of our process has increased its throughput yield from 85% to 97% and reduced non-value activities by 30%. As a result our improvements, our customers have seen improved deliveries.
The green technology of this process utilizes recycled water to cool castings pumped from cooling towers in a closed loop system. Streamlining the nitrogen degassing procedures with automatic controllers provides cleaner metal and reduces the use of nitrogen by 40%. This improved process design has allowed Oberdorfer Aluminum Foundry to exceed customer’s expectations by producing a superior casting, with improved efficiencies, while supporting our efforts to improve the environment.
Oberdorfer Aluminum Casting Foundry, a subsidiary of the Advanced Metals Group, LLC, provides permanent, semi permanent, dry sand and no-bake castings. The Oberdorfer team continues to invest in lean manufacturing & six sigma (staffed black belt) methodology to improve product quality & provide value added operations for its customers.
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