Procurement’s influence extends to every part of the warehouse facility, from sourcing advanced warehouse management systems (WMS) to ensuring warehouse space is optimised for timely delivery of stored goods, lower transportation costs, and reduced shipping costs. This article examines how procurement is shaping the warehousing industry, explores key benefits, and offers insight into future trends.

Warehousing vs Storage: Key Differences in Supply Chain Management

At first glance, the functions of warehousing and storage may seem like the same thing. Both involve storing goods, but they serve different purposes in the supply chain management process. Warehousing includes various warehousing functions beyond simply storing goods, such as order processing, asset protection, and managing inventory to facilitate distribution. Warehouses are complex facilities with capabilities for efficient order fulfillment, inventory management, and supporting distribution centers in a way that’s critical for retail stores and e-commerce.

In contrast, storage facilities or simple storage spaces are primarily for holding inventory without frequent movement. Businesses use storage warehouses to store inventory over an extended period, ideal for finished products or raw materials that don’t need immediate processing. Procurement’s role here typically involves securing contracts for storage space in a storage facility or arranging dedicated space within a warehouse for simple storage of incoming shipments.

Warehouse vs Distribution Center: Distinct Functions in Supply Chains

Understanding the difference between a warehouse and a distribution center is critical in managing logistics effectively. A warehouse focuses on long-term storage of inventory, allowing goods to be stored and accessed when needed by the business or retail store. Distribution centers, by contrast, support efficient warehousing operations by facilitating quick turnover and timely delivery. In distribution centers, goods are processed rapidly and shipped to their next destinations, making them essential for fulfilling orders in industries with high consumer demand, such as e-commerce businesses.

Procurement professionals play distinct roles in these facilities. In warehouses, procurement might focus on acquiring storage systems for physical inventory, tracking inventory levels, and maintaining cost-effective storage solutions. For distribution centers, procurement may need to source order-picking robots, radio frequency identification (RFID) systems, or conveyor belts to support the easy access and quick movement of large quantities of goods.

Types of Warehouses: Tailoring Facilities for Business Needs

Warehouses come in different forms to meet specific requirements across industries. Here are several types of warehouses that play crucial roles in today’s supply chains:

1. Public Warehouses – Public storage warehouses allow businesses to lease storage space on a short- or long-term basis, offering flexibility and scalability for smaller companies or those with fluctuating inventory levels. Procurement teams negotiate rental agreements to manage costs and ensure quality standards in these shared storage facilities.

2. Private Warehouses – Owned or leased by a single business, private warehouses give companies full control over warehousing functions, from managing inventory to configuring order processing. Larger corporations often choose private warehouses as they have consistent demand and need dedicated space to handle high volumes of incoming shipments.

3. Smart Warehouses – These technologically advanced facilities use WMS, automation and AI to minimise human intervention, reduce costs and ensure efficient warehousing operations. Procurement’s role here is to source cutting-edge technology like RFID and inventory tracking software, building a streamlined environment for managing inventory with accuracy.

4. Bonded Warehouses – These are government-licensed facilities used to store goods without immediately paying import taxes. Bonded warehouses benefit companies involved in international trade by enabling them to defer duty payments until items are sold. Procurement teams work closely with customs to ensure compliance and secure bonded warehousing agreements.

5. Cold Storage Warehouses – Designed to store products that require controlled temperatures, such as pharmaceuticals or perishable foods, cold storage warehouses help prevent product spoilage. Procurement professionals here focus on securing specialised equipment like refrigeration systems and energy-efficient cooling technologies.

The Strategic Role of Procurement in Warehouse Management

Procurement’s role in warehousing has evolved significantly, becoming central to optimising warehouse management and reducing operational costs. Effective procurement is not only about fulfilling orders or about sourcing equipment but about building a resilient, flexible warehouse facility that can adapt to changes in demand.

One of the primary responsibilities of procurement is cost control. Procurement professionals secure favourable terms with suppliers for storage solutions, warehouse management systems, and maintenance services, reducing costs while ensuring high service quality. Supplier relationship management also plays a key role, allowing procurement teams to anticipate supply chain disruptions and negotiate with alternative providers if needed, ensuring continuity in warehousing operations.

Additionally, procurement drives efficiency in warehouse operations by ensuring the warehouse facility is equipped to manage inventory accurately. By implementing WMS and tracking inventory levels with RFID, procurement supports logistics management that leads to timely delivery and reduces the risk of stockouts or overstocking.

Benefits of Procurement in Warehousing Operations

When procurement functions strategically within warehouse operations, the benefits can be substantial. Here are some key advantages procurement brings to warehousing:

1. Cost Savings – Effective procurement reduces warehouse facility expenses by sourcing cost-effective equipment, negotiating contracts, and managing supplier relationships to lower costs related to storage and distribution.

2. Enhanced Inventory Management – With a focus on tracking inventory levels and using advanced tools, procurement ensures physical inventory is accurately monitored, preventing inventory shortages and supporting efficient order fulfillment.

3. Sustainability Initiatives – Procurement increasingly plays a role in implementing sustainable practices by sourcing energy-efficient equipment and eco-friendly materials, reducing the carbon footprint of warehousing operations. This aligns with the growing emphasis on regulatory compliance, such as the EU Supply Chain Act, which underscores the importance of sustainability and ethical practices in supply chains.

4. Operational Efficiency – By implementing WMS, RFID systems, and automation, procurement improves warehouse efficiency, allowing for faster order processing and reducing the likelihood of delays.

5. Supplier Diversification – Having multiple suppliers ensures that procurement can mitigate supply chain risks by diversifying sources, reducing dependency on any single supplier, and ensuring resilient warehousing operations. Understanding supplier tiers can further assist in unlocking a wide and diverse supplier base.

Future Trends in Warehousing and Procurement

Technology and sustainability are transforming the warehousing industry. As smart warehousing becomes mainstream, procurement is at the forefront of adopting innovations like IoT, AI, and robotics. These efforts often benefit from applying Design for Supply Chain principles, which integrate procurement and supply chain considerations early in product design. Smart warehouses enable efficient order fulfillment, automated inventory management, and easy access to streamlined warehousing products, reducing the labour required and increasing operational accuracy.

Sustainability is another growing trend, as companies seek to reduce their environmental footprint. Procurement plays an essential role in making warehouses more sustainable by sourcing materials that meet green standards, investing in energy-efficient lighting and cooling systems, and partnering with suppliers who follow ethical practices.

For example, as companies look to minimise shipping costs and carbon emissions, they are increasingly sourcing products from local suppliers, reducing transportation costs, and supporting timely delivery. Additionally, many companies are adopting radio frequency identification technology and automation to cut down on waste, maximise space efficiency, and minimise reliance on physical inventory checks.

The Use of Technology and AI in Warehousing

Technology and artificial intelligence (AI) are reshaping the warehousing industry, helping businesses enhance efficiency, improve inventory management, and reduce costs. In recent years, the demand for quicker and more accurate order fulfillment has led to a wave of technology adoption across warehouses and distribution centers, with procurement teams taking the lead in sourcing and implementing these innovations. From warehouse management systems (WMS) to radio frequency identification (RFID) and automated guided vehicles (AGVs), advanced technologies are driving warehouse operations and fulfillment centers toward unprecedented levels of accuracy and efficiency.

1. Warehouse Management Systems (WMS):
A robust WMS is at the heart of modern warehouse management. By centralising data on inventory levels, order processing and incoming shipments, WMS enables precise tracking of every item within a warehouse facility. Procurement teams play a key role here, sourcing WMS solutions that integrate seamlessly with existing supply chain management systems to provide real-time visibility of inventory storage and movement. This level of tracking allows for efficient order fulfillment, supports accurate inventory management, and reduces both storage space needs and transportation costs.

2. Radio Frequency Identification (RFID) and IoT Sensors:
RFID and IoT (Internet of Things) sensors are instrumental in tracking inventory levels, reducing the risk of misplaced or lost items, and optimising warehouse space. By affixing RFID tags to goods, warehouses can automatically monitor the movement of stored goods, allowing for real-time tracking and improved asset protection. IoT sensors can also monitor environmental factors within storage facilities, ensuring that sensitive goods such as raw materials or perishable items are kept at optimal conditions. Procurement teams are now often responsible for sourcing these technologies, which contribute to both inventory accuracy and cost efficiency in warehousing.

3. Robotics and Automated Guided Vehicles (AGVs):
Robotics and AGVs streamline the handling of large quantities of goods, minimising the need for manual labour. In smart warehouses, robots are deployed to perform tasks such as picking, packing, and transporting items within designated locations, improving order processing speed and accuracy. AGVs, in particular, have proven effective in high-demand environments like e-commerce businesses, where speed is critical. Procurement teams that invest in robotics help reduce costs associated with human error and improve the efficiency of logistics operations, ensuring timely delivery and optimal use of storage space.

4. Artificial Intelligence (AI) and Machine Learning (ML):
AI and ML are increasingly used in warehousing for demand forecasting, inventory management, and supply chain optimisation. Through predictive analytics, AI can anticipate demand surges or slow periods, allowing warehouses to adjust inventory levels accordingly and avoid overstocking or stockouts. Machine learning algorithms also enhance the accuracy of managing inventory by identifying patterns in consumer behavior and adjusting warehousing operations to align with these trends. By procuring AI-powered tools, procurement professionals enable warehouses to become more adaptive, responsive and cost-effective.

5. Automation and Conveyor Systems:
Automation extends beyond robotics, with conveyor systems, automated sorting, and packaging solutions now common in large-scale distribution centers. These systems reduce the need for manual intervention, improving the speed and accuracy of logistics operations. Conveyor systems, in particular, facilitate the movement of products across different sections of a warehouse, making it easy to fulfil orders and distribute goods. For procurement teams, investing in these automated solutions means less dependency on manual labour and greater efficiency in warehouse functions.

6. Digital Twins and Predictive Maintenance:
Digital twin technology is gaining traction as a valuable tool for warehousing, enabling operators to create virtual models of a warehouse facility. These digital replicas allow for real-time monitoring and predictive maintenance, helping to identify potential issues before they impact operations. Predictive maintenance ensures that equipment like conveyor belts and automated systems run smoothly, reducing downtime and associated costs. Procurement teams sourcing digital twin technology facilitate a proactive approach to warehouse management, optimising both functionality and longevity of warehousing assets.

Conclusion

Procurement’s role in warehousing has evolved to become a cornerstone of efficient warehousing operations. As supply chains grow in complexity, procurement and warehousing teams are essential in building flexible, resilient warehouses that reduce costs, optimise logistics operations and meet the needs of an increasingly fast-paced market.

Looking to the future, procurement will continue to drive innovation in warehousing, from smart technology and sustainable practices to cost-effective inventory storage and warehousing products and streamlined logistics management. By partnering with suppliers and leveraging new tools, procurement professionals will play a key role in creating warehouse facilities that are not only efficient but also agile and future-ready.

The post Warehousing – Key Benefits, Trends & Future Outlook appeared first on Fractory.

Most of these parts are sourced from various manufacturers before being assembled onto the body-in-white. In order to make a car, all of these parts must be sourced from within and outside a country in varying quantities. Thus, producing thousands of cars every month requires meticulous deliberation, planning and execution.

The complex process needs to be simplified to enhance accuracy and repeatability. A bill of materials is a tool that helps us achieve just that. This article will explore the concept of a bill of materials, its contents, types, and its role in simplifying complex processes within various departments in different industries.

What Is a Bill of Materials?

A Bill of Materials (BOM) is a product-specific document that provides a detailed breakdown of a product into assemblies and sub-assemblies. It serves as a comprehensive blueprint, outlining the various components involved in the manufacturing process. Think of it as a grocery list for making your assembly.

A bill of materials is an important and useful document, it serves as the foundation for production planning systems. As the number of parts in a product increases, it becomes increasingly difficult to manage the availability of all the components in sufficient quantities for the assembly process. The unavailability of just one part can halt the entire assembly line, costing the company thousands of dollars in lost productivity.

To prevent this, companies use a bill of materials to plan and track component purchases, optimise inventory levels and reduce waste. When used correctly, it enables a more systematic and deliberate process, minimising unplanned downtime and errors while ensuring operations run at the lowest possible cost.

What Is Included in a Bill of Materials?

A bill of materials can take on different forms. It has different components depending on the department to which it belongs.

For instance, a manufacturing bill of materials includes details, such as the product code, part name and number, quantity, description, colour, size, and the process in which it will be used to make the final product.

A sales bill of materials includes sales-relevant information, such as product prices, shipping details, part weight and dimensions, payment terms, tax rates, etc.

Thus, the BOM may include all the information that a department needs for smooth operations.

Bill of Materials BOM

Bill of Materials (BOM) Structure

A Bill of Materials (BOM) follows a standard structure. At the top is the finished product, which branches into sub-assemblies and their individual components as the hierarchy progresses downward. The BOM hierarchy resembles a pyramid, with the simplest components, such as fasteners, forming the base. These components combine with others at successive levels, ultimately culminating in the finished product at the apex.

Some BOM layouts may also include orthographic projections of a product, with all components tabulated at the bottom along with their details.

The structure of a bill of materials may also change depending on whether it is a single-level BOM or multi-level BOM:

• A single-level BOM places the finished product at the top, with individual components listed just beneath it. There are no sub-assemblies.
• A multi-level BOM is required for parts that have a high number of components and need more than one tier of hierarchy. The product’s assembly is broken down into sub-assemblies, tier after tier, until the individual components are reached.

A comprehensive bill of materials should include the following information:

Product or Assembly Name – Identifies the product or assembly, which is especially important for companies managing multiple product lines.

Part Name – Identifies the part and includes relevant details associated with it.

Part Number – A unique numeric or alphanumeric identifier is assigned to each part to ensure easy identification. A product may include several similar parts that vary in size or shape. For instance, bolts, which are commonly used as fasteners, can be differentiated by assigning a unique identifier to each type. This approach allows for more effective tracking and management of availability and usage.

Description – Prevents confusion between similar parts by providing any unique information about a part that may be overlooked at first glance. It may include details, such as colour or dimensions.

Quantity – Indicates the number of components in the final product. This helps to plan purchasing and manufacturing activities. Different components may have different units of measurement. The unit may be located in an adjacent column or in the quantity column itself.

BOM Level – A multi-level BOM consists of several levels. The Bill of Materials (BOM) also specifies the level for every component based on its position in the BOM hierarchy.

Manufacturer Details – Including manufacturer details is essential when a product consists of components or sub-assemblies sourced from multiple suppliers.

Part Phase – The term “part phase” refers to the stage a part is currently in. For a New Product Introduction (NPI) part, the phase might be labeled as “unreleased” or “in design.” For a finalised part that has reached the production stage and is on the machine shop floor, may be marked as “in production.” The part phase may sometimes also include the version of the parts, as they evolve through optimisations.

Alternate Part – A column may be added to the BOM to inform the reader of alternative parts to be used if the original part is unavailable.

Component Cost – The component’s unit cost may also be mentioned alongside their name in some bills of materials. This helps to understand the cost weightage of each component.

Procurement Type – The bill of materials may also specify the procurement method for a particular component. For items readily available in the market, the BOM may refer to them as “off-the-shelf”. custom-made parts, on the other hand, will be referred to as “made-to-specification”. This distinction helps us understand that certain parts may have longer lead times than others, enabling the team to plan manufacturing and purchasing activities accordingly.

Priority Analysis – The priority analysis column indicates which components or parts have a higher priority, typically requiring greater monetary investments or longer lead times. This helps to distinguish between critical parts and common parts.

BOM Notes & Comments – A Bill of Materials (BOM) also includes a notes/comments section for documenting any changes as the project progresses. For clarity, this section may also include diagrams and assemblies of relevant parts.

Types of Bills of Materials

Bills of materials are widely used in most product-based companies.

Although BOMs originated in manufacturing, they have gradually transitioned to other organisational functions. Today, in addition to a Manufacturing BOM, there are various types of bills of materials: Sales BOM, Engineering BOM, Production BOM, Purchasing BOM, Service BOM, and CAD BOM.

Each Bill of Materials (BOM) plays a crucial role in product development, and all of these BOMs are essential for the relevant department to support its functions and processes. Let’s take a look at two of the most important bills of materials to understand what they offer.

Engineering BOM

The engineering department prepares the Engineering Bill of Materials (EBOM) to define their product. It has a hierarchical structure with detailed specifications of each component, such as part number and tolerances. The EBOM is usually created using Computer-Aided Design (CAD) or Electronic Design Automation (EDA) software.

An EBOM covers only engineering concerns, such as form, fit and function. It does not concern itself with how parts are manufactured or procured. The EBOM is one of the first BOMs created in product development.

Manufacturing BOM

The Manufacturing Bill of Materials (MBOM) is created by the manufacturing team to build the product. Unlike the EBOM, it has a more visual format, with diagrams and/or flowcharts. Since manufacturing can only begin once the design is finalised, the Manufacturing BOMs are created after EBOMs.

The manufacturing BOM focuses on how a product is made. It contains detailed information about the manufacturing process, tooling, work instructions, and assembly stages.

Information Flow Between BOMs

All the different BOMs mentioned in the previous section are interconnected. Information flows from the top to the bottom through all the different bills of materials.

At the start of product development, only the requirements and specifications of the part are available. Using this information, an early bill of materials is generated, listing the assemblies and parts required for the final product.

The engineering department is the end user of the early BOM, as it helps them get a head start. They use the information from the early BOM to generate the Engineering BOM. The Engineering BOM is more comprehensive, benefiting departments like manufacturing, purchasing and servicing.

Each department uses the Engineering BOM to generate its own BOMs: Manufacturing BOM, Purchasing BOM and Service BOM. For example, if the Engineering BOM specifies that a part requires 6 M12 bolts, the purchasing department would order 600 M12 screws if the company plans to manufacture 100 finished products. So, in a way, the supporting departments are the actual consumers of the Engineering BOM.

In complex industries, such as the automotive and aerospace, all bills of materials play an important role. The components that form the product may be manufactured in-house or sourced from Tier 1, Tier 2 and Tier 3 suppliers. Parallel products may be manufactured simultaneously. Some components may be common to multiple products, while others may be unique to each product.

Effective optimisation of inventory and supply chain management requires a purchasing bill of materials that serves as a reference point for all stakeholders. This ensures alignment and prevents both shortages and wastage. However, not all types of BOMs are necessary for every company. Smaller companies, that do not have high purchasing requirements, can operate without a purchasing BOM.

How to Create a Bill of Materials

A bill of materials needs to be as comprehensive as possible without including any unnecessary information. Let’s break down the process of creating a general bill of materials when starting from scratch:

Step 1: Understand the Product

Start by defining the product and the goal of the bill of materials. By understanding the objective, irrelevant information can be filtered out. Pay attention to the design, specifications and all product documentation.

Step 2: List All Parts

Break the product down into its sub-assemblies, components and materials. Try to delve as deep as possible to identify each component separately.

Step 3: Identify Part Numbers and Other Part-Specific Information

In this step, gather specific information about each part of the Bill of Materials (BOM). This could be the manufacturer’s part number, description, part colour, dimensions, weight or any other relevant measurement. You may want to include part revision numbers to track changes over time.

Step 4: Create the Bill of Materials (BOM) Structure

The product determines the format. When dealing with a product with just a few components, a single-level BOM is efficient. For complex parts, a multi-level BOM would be more appropriate. Choose the relevant information gathered in Step 3 and organise the components in a hierarchical structure. The individual components are at the bottom. Moving up, these components are combined to form sub-assemblies that eventually lead to the final product. The final structure should look like a tree root or a pyramid.

Additional Tips

1. Include sufficient visual aids, such as drawings and diagrams.

2. Mention the manufacturers and suppliers of the different components in the BOM.

3. Manual bills of materials are prone to errors and difficult to modify. Invest in good BOM software for a better experience.

4. For clarity and consistency, use standard formats, terms and units.

Optimising a Bill of Materials

If you already have a BOM, you may be looking for tips to improve it. A bill of materials is an excellent tool, but it needs consistent maintenance. The following tips can help you optimise your current BOM to ensure you have the best version at all times.

Review at Regular Intervals

The most important feature of a BOM is that it accurately represents a process. However, product changes and updates occur regularly in most products. Therefore, BOMs have to be reviewed and updated regularly to reflect these changes correctly.

Cross-Functional Review

Discussing BOM among the various departments can reveal any missed information and how it could be included. This would make the BOM more accurate and complete than before.

Add Visual Aids

Add visual aids where necessary, such as images, diagrams and drawings, to enhance clarity and understanding of complex assemblies.

Integrate with Other Systems

Integrating the BOM with other systems, such as ERP and PLM, can make editing easier and allow better version control.

Benefits of Using a Bill of Materials

As pointed out in previous sections, a bill of materials serves various functions in different departments. Naturally, it also provides different benefits to each of them. In this section, you’ll find the benefits offered by the two most common bills of materials: the Engineering BOM and the Manufacturing BOM.

Benefits of an Engineering BOM (EBOM)

The Engineering BOM provides immense value not only to the engineering department but also to departments that support engineering, such as sales, purchasing and manufacturing. Investing in this tool helps engineering departments enhance efficiency and achieve their objectives. Let’s take a look at some specific advantages that an EBOM provides:

Improved Product Quality – The engineering bill of materials helps to enhance product quality over time by reinforcing design practices, minimising errors and reducing the need for rework.

Design Accuracy – Having a standardised EBOM enables the team to have a clear understanding of the various components, their design specifications and functionality. This enhances overall design accuracy.

Avoiding Downstream Problems – The team creates the EBOM during the design phase. This allows the engineers to identify and resolve potential issues well in advance, preventing costly corrections downstream.

Effective Communication – A picture speaks a thousand words. An EBOM is a comprehensive document that systematically lays out the form, fit and function of the proposed product and its components. This enables effective communication among the interdisciplinary teams involved in the product development process.

Version Control – A product may undergo many changes throughout the production process. These changes need to be tracked, documented and communicated to all stakeholders as soon as they are finalised. An EBOM with version control capabilities allows us to manage changes during the design phase and ensures that everyone has access to the most up-to-date and accurate information.

Synergy with PLM Software – The engineering bill of materials can be integrated with Product Lifecycle Management (PLM) software to oversee product data throughout its lifecycle. The integration is fast and seamless, offering the benefits of centralisation.

Failure Cause Identification – An accurate BOM helps identify the cause of product failure and facilitates the replacement of faulty components or materials.

Benefits of a Manufacturing BOM (MBOM)

The Manufacturing BOM serves as the central document for the manufacturing team. It is derived from the Engineering BOM and contains all the information relevant to manufacturing the product. Having an exhaustive and well-updated Manufacturing Bill of Materials (MBOM) provides the following advantages.

Improved Production Planning – The MBOM contains a comprehensive list of components along with all the required specifications and essential raw materials needed for manufacturing. This helps in accurate resource allocation and production planning. The BOM is also a prerequisite for designing Enterprise Resource Planning (ERP) and Materials Requirement Planning (MRP) systems.

Errors Minimised – Most errors in a manufacturing setup occur during the manufacturing and assembly of parts. Having a BOM standardises these manufacturing processes for all the concerned employees and reduces the chances of errors.

Improved Inventory Management – A clear and well-structured BOM helps maintain the appropriate inventory levels for production needs. It enables the anticipation of demand and ensures timely fulfillment while minimising logistics costs. This approach prevents common inventory issues such as stockouts, overstocking and backorders, as well as their cascading effects, including lost productivity, production delays and downtime.

Time Savings – Having a centralised document containing all the part details leads to time savings across the board. Details, such as part numbers, part colours and the fabrication process in which they will be used, can be easily revised by referring to the MBOM in case of any confusion. Items can be located within minutes in the store. Small time savings add up and improve the overall productivity and efficiency of the manufacturing operations.

Budget Control – An MBOM can reduce waste and improve time management, ultimately helping an organisation maintain control over budget.

Conclusion

All in all, a bill of materials is an essential tool for any company that wants to improve its production efficiency. A good BOM, through specifications, quantities and component details, improves collaboration among the various teams and streamlines workflows.

The benefits reach beyond the shop floor. A well-structured BOM allows to control inventory, production cost and product quality. A direct beneficial impact can seen in the accuracy and efficiency of the setup, and an indirect impact appears in customer satisfaction.

The post Bill of Materials – What It Is, How It Works & Its Benefits appeared first on Fractory.

Many large multinational corporations have faced allegations of child labour in their supply chain. This type of human rights abuse, along with environmental destruction, has long been a hidden consequence of global sourcing.

The European Supply Chain Act, officially known as the EU Corporate Sustainability Due Diligence Directive (CSDDD), is poised to reshape the business landscape. With the legislation expected to push thousands of companies worldwide towards more sustainable practices, it’s time to delve into what this act entails, how it will affect businesses, and what they need to do to prepare.

What Is the Objective of the EU Supply Chain Law?

The European Supply Chain Act is designed to ensure that companies operating within the EU are accountable for the human rights and environmental risks associated with their supply chain activities. Essentially, it holds businesses liable for any violations that occur, not only within their own operations but throughout their entire supply chain, from direct suppliers to indirect suppliers.

The law is closely aligned with the EU Corporate Sustainability Due Diligence Directive (CSDDD), which establishes the framework for corporate sustainability. The CSDDD encourages companies to adopt responsible business practices that respect human rights and minimise their environmental impact. Both these directives work in tandem to ensure businesses conduct thorough due diligence when sourcing from global markets.

What Are the Obligations for Companies?

Companies operating within the European Union must comply with rigorous due diligence requirements under the European Supply Chain Act. This includes evaluating potential risks throughout their supply chains and procurement activities, drawing on the benchmark established by Germany’s Supply Chain Act for responsible sourcing and accountability.

Companies are required to identify, prevent and mitigate adverse human rights and environmental impacts including global warming throughout their overall supply chain, including indirect suppliers.

Their responsibility extends to the actions of their suppliers and subcontractors, aligning with the proactive measures outlined in Germany’s legislation.

To comply with the EU Supply Chain Law, companies must adhere to several due diligence obligations:

Due Diligence Requirements: Businesses are required to establish a robust due diligence process that identifies, prevents and mitigates any adverse human rights or environmental impacts within their supply chain.

Scope of Responsibility: Companies are not only accountable for their internal operations but also for their indirect business partners and suppliers. This means they need to assess risks throughout their global value chains.

Reporting Requirements: Transparency is essential. Companies must publicly disclose their due diligence efforts, outlining the steps taken to prevent and address risks. This new approach places significant responsibility on corporations to ensure they collaborate with ethical suppliers, regardless of their geographical location.

Who Is Affected by the EU Supply Chain Directive?

Not all companies are subject to the EU Supply Chain Act. The legislation applies to businesses based on their size and turnover. Larger corporations, particularly those with complex supply chains, are the primary targets.

Size and Scope: Initially, the EU Corporate Sustainability Due Diligence Directive (CSDDD or CS3D) targets companies with over 1,000 employees and a global turnover exceeding €450 million. Over time, this will expand to include smaller businesses.

Global Reach: The law does not solely impact EU-based companies; it also applies to non-EU companies with significant business activities in the European Union. Therefore, multinational corporations with business partners or operations in the EU will also need to comply as well.

Contradicting Numbers: Interestingly, the scope of the CSDDD has changed over time. Initially, it impacted companies with 500 employees and a €150 million turnover. After thorough negotiations, the final numbers were increased to 1,000 employees and €450 million. This shift caused significant debate as to which companies would fall under the new law.

When Will Companies Have to Comply?

Compliance with the European Supply Chain Act is structured in phases, gradually imposing obligations on companies based on their size, employee count and revenue. This phased approach ensures that larger corporations are targeted initially, with smaller businesses having additional time to adapt to the new regulations. The timeline for compliance is as follows:

Compliance Phases

2027: Large Enterprises (5,000+ Employees / €1.5 Billion Turnover)
The first wave of compliance begins in 2027, primarily targeting the largest of enterprises. These are companies with over 5,000 employees and an annual global turnover of €1.5 billion or more. Since these businesses typically have more complex supply chains and global operations, the impact of the law on them is expected to be significant. Large companies will likely face increased scrutiny, requiring them to develop comprehensive due diligence procedures to address internationally recognised human rights abuses, environmental risks and ethical sourcing.

2028: Mid-Sized Enterprises (3,000+ Employees / €900 Million Turnover)
The second phase, commencing in 2028, broadens the scope to include companies with at least 3,000 employees and a turnover of €900 million or more. While these businesses are smaller than the largest multinational corporations, they still operate across borders and face considerable supply chain risks.

2029: Smaller Enterprises (1,000+ Employees / €450 Million Turnover)
By mid 2029, enterprises with 1,000 or more employees and an annual turnover of €450 million will be required to comply. While these companies may not have as extensive supply chains like the companies in previous batches, they must still perform adequate due diligence, particularly if they operate in high-risk sectors such as manufacturing, raw materials or textiles.

Additional Considerations for Compliance

National Implementation Variations: Although the EU Supply Chain Act is an overarching directive, the specifics of how it will be transposed into national law will vary across EU member states. Companies operating in multiple EU jurisdictions must stay updated on the specific legal timelines and obligations for each country, as some may impose stricter regulations or shorter deadlines.

Early Preparation: Companies should not wait until the formal deadlines to start compliance efforts. Early preparation will be key in minimising disruptions to business operations and supply chains. This includes assessing existing CSR (Corporate Social Responsibility) policies and aligning them with the directive’s requirements, as well as incorporating sustainability KPIs into their business performance metrics.

Use of Technology for Compliance: Many companies, particularly larger ones, are expected to invest in supply chain management software and risk assessment tools to efficiently monitor and audit their global supply chain activities for potential risks. These technologies can automate due diligence processes and provide real-time insights into supplier performance.

Penalties for Non-Compliance: Penalties for failing to meet the directive’s standards can vary depending on the severity of the breach, ranging from financial penalties to potential legal liabilities for any adverse impacts caused. Large corporations are likely to face heavier fines and more public scrutiny, while smaller enterprises may receive warnings or lighter penalties, reflecting their capacity to implement compliance measure.

How Can Companies Prepare for the Supply Chain Act?

Preparation is key to avoiding non-compliance penalties. Here’s how companies can get ready:

Risk Assessment: Businesses must start by conducting comprehensive risk management across their entire supply chain, including indirect suppliers. This should encompass both human rights and environmental risks, ensuring that a robust risk management system is in place to identify, prevent and mitigate potential adverse impacts

Supplier Engagement: Companies need to establish a strong business relationship with their suppliers to ensure they meet the required corporate sustainability due diligence standards. Engaging suppliers early will help foster a business model that aligns with the new regulations.

Internal Policies and Procedures: Firms must implement a robust risk management system to monitor compliance throughout their supply chains. This includes establishing clear policies on responsible sourcing and ensuring that suppliers adhere to these practices.

Training and Capacity Building: Providing training to employees and management is essential to ensure that everyone understands their due diligence obligations under the new directive.

How Will the EU Supply Chain Directive Affect Companies Operating in Multiple EU Member States?

One of the most significant challenges for businesses operating across various jurisdictions is the potential for discrepancies in how national laws are implemented. Here are some key considerations:

Harmonisation and Consistency: The EU Supply Chain Law aims to create consistency in standards, thereby reducing the regulatory burden for companies operating across different EU member states.

National Implementations: However, variations may still arise as individual states adopt the directive, leading to potential differences in enforcement.

Challenges and Opportunities: Businesses may face increased administrative burdens as they navigate these differences. Nevertheless, this also presents an opportunity to develop a sustainable economy and gain a competitive advantage by leading the way in responsible business practices.

What’s Next for the EU Supply Chain Directive?

The EU Supply Chain Directive is evolving to address global challenges and promote corporate accountability, in line with the Paris Agreement‘s goals of mitigating climate change and promoting sustainable development. Expect amendments and updates as the legislation adapts to changing trends. International cooperation is also gaining momentum, aiming for harmonised supply chain laws worldwide, further supporting the objectives of the Paris Agreement.

Enforcement will be through administrative supervision by designated national authorities and civil liability for companies that fail to conduct due diligence. The European Network of Supervisory Authorities will foster a coordinated approach across member states, ensuring effective and consistent enforcement and contributing to the broader implementation of the Paris Agreement.

Conclusion

The European Supply Chain Act represents a significant step forward in ensuring corporate due diligence across global markets. By addressing internationally recognised human rights abuses and environmental damage in global value chains, the act aims to foster a more ethical and transparent business landscape.

Companies must begin preparing now and adapting their business models to meet these new challenges head-on. The future of supply chain management lies in sustainability and companies that embrace these changes will not only comply but also thrive in a more socially responsible global economy.

The post European Supply Chain Act – Key Insights appeared first on Fractory.

The implications of unmanaged tail spend extend far beyond financial loss. It can impact project timelines, compromise quality and hinder innovation. By diverting resources from critical engineering initiatives, tail spend can stifle growth and competitive advantage.

This article delves into the hidden costs of tail spend in the engineering sector and provides actionable strategies to reclaim control. By harnessing the power of data analytics and implementing effective procurement processes, engineering organisations can unlock substantial cost savings and optimise their operations.

What Is Tail Spend?

Tail spend refers to the portion of an organisation’s expenditure that is made up of high-volume, low-value, one-off purchases and transactions. Typically accounting for one-off purchases or 80% of transactions but only 20% of total spend (Pareto Principle), it often involves purchases made outside of formal procurement processes, otherwise known as “rogue spending.”

This category of spending can encompass a wide range of items, from office supplies and IT equipment to maintenance services and professional fees. Due to its fragmented nature and insignificance, it is frequently overlooked and poorly managed.

Despite its seemingly insignificant nature, the cumulative impact of rogue spending can be substantial. By understanding the strategic importance of addressing this area and conducting analysis, organisations can uncover significant cost-saving opportunities and improve overall procurement efficiency.

The Impact of Tail Spend on Engineering Projects

Unmanaged tail spend can have far-reaching consequences. This can ultimately hinder growth and competitiveness through examples such as:

• Budgetary Constraints

• Time Delays

• Quality Compromises: Resource Allocation

• Supply Chain Disruptions

Benefits of Proper Tail Spend Management

Effective tail spend management offers numerous advantages:

• Cost Reduction: Consolidating low-value purchases, significant cost savings can be achieved through volume discounts, price negotiations, and eliminating unnecessary spending.

• Improved Efficiency: Streamlined procurement processes and reduced maverick spending free up valuable resources, allowing teams to focus on core engineering activities.

• Enhanced Visibility: Greater spend awareness and improved data quality can provide valuable insights into spending habits and opportunities for optimisation.

• Risk Mitigation: Centralising procurement and working with approved suppliers reduces the risk of fraud, supply chain disruptions, and quality issues.

• Data-Driven Decision Making: Comprehensive spend data enables informed decision-making, allowing organisations to identify cost-saving opportunities and allocate resources effectively.

• Improved Compliance: Implementing standardised procurement processes ensures adherence to company policies and regulatory requirements.

Strategies for Taming Engineering Tail Spend

Strategies to manage tail spend requires a structured approach that combines data analysis, process optimisation and supplier management. By implementing the following strategies, procurement departments can significantly reduce their exposure to hidden costs.

Spend Analysis and Categorisation:

• Conduct a thorough analysis of historical procurement spend data to identify high-value, low-volume items contributing to tail spend, consider the Pareto principle.

• Categorise spend based on factors such as supplier, product category, and spend volume.

• Prioritise categories for targeted intervention based on their impact on overall costs.

Improved Procurement Processes:

• Implement robust procurement processes to capture all spending, including low-value items.

• Establish clear purchasing guidelines and authorisation levels to reduce maverick spending.

• Encourage the use of preferred suppliers and contract management to leverage economies of scale.

Supplier Relationship Management:

• Build strong relationships with key suppliers to negotiate better terms and conditions.

• Consolidate supplier base to reduce transaction costs and increase bargaining power.

• Explore opportunities for collaboration and innovation with strategic suppliers.

Data-Driven Decision Making:

• Utilise data analytics tools and digital platforms to identify spending patterns, track transactions and anomalies.

• Leverage predictive analytics to forecast future spend and optimise inventory levels.

• Use data to measure the impact of tail spend reduction initiatives.

Category Management:

• Establish dedicated category managers for high-spend categories within tail spend.

• Conduct regular market analysis and supplier performance evaluations.

• Develop category strategies to optimise spend and reduce costs.

By implementing these strategies, it is possible to gain control over tail spend, improve financial performance, and improve internal processes to enhance operational efficiency.

Case Studies: Engineering Organisations That Conquered Tail Spend

Here are a few examples of organisations that have effectively tackled tail spend:

Case Study 1: Aerospace Engineering Firm

A leading aerospace engineering firm implemented a program to reduce costs and improve operational efficiency. By leveraging advanced data and spend analysis, they identified significant savings opportunities in indirect spend areas such as MRO supplies, office equipment and IT services. By consolidating suppliers the firm achieved a 15% reduction in tail spend within the first year.

Case Study 2: Civil Engineering Contractor

A large civil engineering contractor faced challenges with maverick spend on construction materials, equipment rentals and subcontractor services. By implementing a cloud-based P2P platform and integrating spend analytics with project management systems, they gained visibility into spending patterns, payment terms and identified opportunities for potential cost savings. Through supplier negotiations and cost-saving strategies, the contractor reduced tail spend by 10%, improving project profitability.

Case Study 3: Automotive Engineering Company

An automotive engineering company sought to streamline its processes and reduce costs associated with tail spend on engineering tools, software and consumables. By the procurement department implementing a purchase-to-pay solution and establishing clear purchasing guidelines, the company achieved a 20% reduction in tail spend and improved compliance.

Challenges of Implementing Tail Spend Management in Engineering

While the benefits of effective tail spend management are clear, engineering organisations often face unique challenges in implementing successful strategies to manage tail spend.

Data Quality and Accessibility: Engineering environments often generate complex and fragmented data, making it difficult to accurately capture and analyse a company’s spend information. Inconsistencies in data formats, missing information and disparate systems can hinder effective analysis.

Decentralised Decision Making: The nature of engineering projects often involves multiple stakeholders with a number of suppliers and varying levels of authority. This can lead to maverick spending and difficulty in enforcing procurement policies and moving towards strategically managed spend coverage.

Rapid Technological Advancements: The engineering sector experiences rapid technological changes, which can impact the types of goods and services required. This dynamic environment can make it challenging to maintain up-to-date supplier information and category management strategies.

Complex Supply Chains: Engineering projects often involve intricate supply chains with numerous suppliers, making it difficult to gain visibility and control over tail spend.

Project-Based Nature of Work: The project-based nature of engineering work can create challenges in managing tail spend, as spending patterns may fluctuate significantly over time.

Overcoming these challenges requires a combination of technology, process improvement and change management.

Tail spend is no longer a hidden cost; it’s a clear and present threat to your bottom line. By ignoring it, you risk sacrificing critical resources, delaying projects and compromising quality.

It’s time to take action. Identify the low-hanging fruit and implement quick wins to reduce costs immediately. Invest in key procurement processes, technology and data analytics to gain deeper insights into your spending patterns. Build strong relationships with key suppliers to negotiate better terms. And most importantly, empower your procurement team to drive change.

By taking decisive steps to manage your tail spend, you can unlock significant savings, gain a key competitive advantage, improve operational efficiency, and position your engineering business for long-term success.

The post Optimising Tail Spend in Engineering: Unlock Savings & Boost Efficiency appeared first on Fractory.

In this article, we’ll dive into the modern sand casting process, examining how it works and why it remains one of the most widely used metal casting techniques even thousands of years after its inception.

What Is Sand Casting?

Sand casting, or sand moulded casting, is a metal fabrication process that uses dies made from sand to create metal products. Sand is easily mouldable with common objects. After shaping it as desired, hot molten metal is poured into the mould. As the metal cools, it takes on the shape of the mould as it solidifies. The final metal product is then extracted from the sand mould and undergoes finishing before being put to use.

Using the sand casting technique, products of all sizes and complexity levels can be manufactured. It can be used to cast items as small as pins or as large as railway locomotives. Additionally, it is compatible with a wide range of metals, including cast iron, malleable iron, steel, nickel alloys, copper alloys, aluminium alloys, and magnesium alloys.

Its versatility makes sand casting the most widely-used casting process in the world, with over 60% of all cast metal products being made using this method.

Properties of Moulding Sand

While there are many different types of sands to choose from, not all of them are suitable for the casting process. Each of them exhibits certain traits that may or may not align with the project requirements.

Depending on the casting process and metal, the right combination of properties in the moulding sand is needed. To enhance cohesion, special additives and binders can be added to the basic sand, clay, and water mixture.

These binders, which can be organic or inorganic, include cereals, ground pitch, sea coal, gilsonite, fuel oil, wood flour, silica flour, iron oxide, and pearlite among others. Some of these binders have contradicting effects but trade-offs are often necessary to balance the properties for specific casting applications.

The four most common types of sand used for casting are green sand, dry sand, sodium silicate and resin sand:

1. Green sand is called so because it is essentially raw sand mixed with water. It exhibits a clay-like consistency. Green sand offers a low-cost option for casting sand with good reusability and is compatible with high production rates. However, its low malleability can cause the mould to collapse under certain situations. It also has a propensity to create surface defects.

2. Dry sand, on the other hand, is a moulding sand that uses clay and contains very little water acting as the binding agent. It holds its shape quite well once rammed into place. A benefit of dry sand is that it creates very little steam during the filling stage, which in the case of more moist sands, can lead to mould fracturing if left unchecked.

3. Sodium silicate, aka water glass, is a special sand that uses a sodium silicate binder to integrate the sand. Sodium silicate can create more intricate or complex shapes than green and dry sand.

4. Resin sand, aka Furan sand, is another popular sand used for sand casting It uses a furfuryl alcohol resin to make a coherent mass out of the sand. The robust and highly stable compound has very little tendency to break down and provides excellent dimensional accuracy and surface finish. However, it is the most expensive of all sands. It also has a higher lead time.

Casting engineers choose the type of sand based on the metal, product geometry and tolerance limits. But no matter the specifications, they always screen a sand type for the following properties:

Refractoriness

Refractoriness is a material’s property that allows it to withstand thermal shocks and burning when subjected to high temperatures. The sand serves as a refractory material for molten metal and thus needs to have a high melting point. The selection of sand for casting is largely influenced by the process temperature. If the refractoriness is insufficient, the sand will melt and fuse to the casting.

For many metals, such as aluminium, the sand only needs to withstand a temperature of 700 degrees Celsius. However, sands for steel castings need to withstand at least 1500 degrees Celsius as the melting point is higher.

Permeability

The sand must vent steam and other gases generated during the casting process. Each unit of water in the mould produces 1600 units of steam.

If the gases and steam get trapped, it can cause defects such as blowholes and gas holes in the final product. Their removal is crucial to obtain a good quality finish. Thus, permeability is a crucial property in sand for achieving a high-quality finished product.

The properties of moulding sand are influenced by the grain size and distribution: small grains increase mould strength but reduce permeability, while larger grains enhance permeability. Fine grains yield a smooth surface finish on castings but have low permeability, whereas coarse grains provide higher permeability but a rougher finish.

High Thermal Conductivity

Thermal conductivity is the property of a material that allows heat to flow through it. Efficient heat flow leads to quicker cooling of the molten metal. Sands with high thermal conductivity are required to transfer the heat from the molten metal to the atmosphere.

Low Thermal Expansion

Thermal expansion is the increase or decrease in the volume of a material when heat is added or removed, respectively. For the sand casting process, sand with a very low thermal expansion is needed. This type of sand will maintain its shape during various stages of the casting process, including the pouring of liquid metal and subsequent cooling.

Flowability

The ability of sand to flow into smaller areas, such as cavities, depressions, and deep channels of the pattern, determines whether we can use it for casting complex shapes. Sand with higher flowability will fill all the features of a pattern without requiring external pressure.

A highly flowable sand is not needed for simple shapes, such as a manhole cover, but it may be required for something more complex like a sculpture. The level of flowability needed may therefore be determined on a case-by-case basis.

Cost

The cost can also vary significantly from sand to sand. Silica sand, for instance, has high availability but also issues like dimensional instability and the tendency to burn or even explode to form sub-micron-sized particles under thermal shock. Silicosis is also an extremely concerning issue with workers being exposed to silica for extensive periods. Olivine and chromite sand, on the other hand, are more expensive and less available but do not have the above-mentioned issues.

Sand Casting Process

Sand Casting Process

The casting process is straightforward for simple products. A cavity with the desired shape is created, and molten metal is poured into it through a vertical channel. Once the metal solidifies, it is extracted by removing the mould sand around it.

However, with complex shapes, aspects such as how to fill the mould, remove excess metal, achieve a high-quality surface finish, and ensure the optimum temperature and velocity of the molten metal for uniform filling must be carefully considered.

Let’s explore a typical sand casting process in more detail:

1. Mould Creation

The mould is created using a pattern, which is a replica of the desired product. The pattern may be made from a different material or process, such as machining or additive manufacturing, but it has the same shape and dimensions as the final product. Multiple moulds can be created using a single pattern.

The pattern is separated into two parts along the centreline of the shape. Each half is then placed in separate sandboxes, and the sand mixture is packed around them to create impressions of the patterns in the sand.

Once the patterns are removed from the sand, the two sandboxes are placed on top of each other, securing them to form the complete mould. The top half and bottom half are referred to as the cope and drag, respectively. The mould cavity thus generated has the negative shape of the product. For example, a protrusion on the final product appears as a depression in the mould.

2. Gating System Creation

The gating system provides a pathway for the molten metal to flow into the cavity. A well-designed system can be crucial for the quality of the product. An effective gating system is simple, efficient, and minimises turbulence. It also traps any gas or slag present in the molten metal.

Key components of the gating system requiring careful design include:

• Pouring Basin and Sprue – The pouring basin serves as the funnel-shaped entry point for the molten metal. The metal flows into the sprue from the pouring basin, moving under gravity towards the cavity.

• Runners – Runners are horizontal channels for the molten metal to reach the die cavity from the sprue.

• Gates – Gates are the entry points of the die cavity, ensuring a smooth flow of the molten metal into the die cavity, maintaining pressure, and preventing flashing. They also help restrict any slag from entering the die cavity.

• Risers – To counteract shrinkage as the metal cools, risers serve as reservoirs in the gating system, storing extra molten metal. As the metal begins to shrink, risers provide additional material to the cavity, preventing metal shortages.

• Cores – When a product requires a hollow section or cavity, a solid sand insert called a core is placed inside the die to form the intended cavity. The molten metal fills around the core, creating the cavity in the final casting. Chaplets hold the core in place during casting.

3. Pouring the Molten Metal

The molten metal is poured from the top into the cavity. The volume of metal used slightly exceeds that of the product to ensure that some excess material is stored in the risers.

4. Solidification into Casting

Once the die cavity is filled, the casting is allowed to cool. Natural or forced cooling may be applied depending on the metal and process. Proper cooling is essential for achieving the desired properties and maintaining dimensional accuracy in the final product.

5. Shakeout and Sand Recovery

Shakeout is the process of removing the sand castings from the mould. The sand is shaken and shifted to separate the solidified casting, which is then sent for final finishing operations, while sand recovery begins.

Since not all of the sand can be recovered, some of the old sand is replaced with fresh sand for future sand casting processes. To restore the sand’s properties for reuse, mechanical, chemical, and thermal treatments may be applied, along with adjustments to its composition by compensating for lost moisture and additives.

Advantages of Sand Casting

Despite the development of many advanced technologies in recent decades, sand casting remains one of the most popular metal fabrication processes. Its unique advantages make it indispensable in the modern manufacturing landscape. Today, sand casting is often automated, enhancing its adaptability and efficiency to meet the demands of contemporary production environments. Here are some key advantages that make sand casting such a valuable process.

Suitable for all types of production

Sand casting is compatible with various production setups, allowing for single-piece, batch, or mass production. This method is extensively used in industries like automotive, defence, agriculture, mining, construction, healthcare, and renewable energy.

In the automotive industry, sand casting is used for developing prototypes, engine blocks, cylinder heads, and various IC engine parts. Its application has also expanded to EV manufacturing, where sand casting is employed to produce structural components, motor housings, battery casings, and more.

There is almost no limitation on size as well. Products ranging from a few grams to a few tons in mass can be cast with mathematical precision.

Cost-efficient

One of the primary factors that drive various sectors to adopt sand casting technology is cost. Sand casting is significantly more cost-effective compared to other casting processes. The sand can be reused for future castings with minimal processing.

The automation in high-volume production also reduces the cost per piece while ensuring consistent and reliable quality. Sand casting also incurs low tooling costs compared to other casting methods.

Suitable for all metals

Sand casting can work with almost any ferrous or non-ferrous metal alloy. Examples include gold, iron, lead, and titanium. The only requirement is that it should melt and flow as a liquid metal into the mould. This flexibility allows foundries to work with a wide range of metals without requiring significant process or equipment modifications.

Fast process

Although processes like centrifugal casting can be more efficient for specific shapes, sand casting offers quick turnaround times both for prototyping and large-scale applications.

Limitations of Sand Casting

All manufacturing processes involve trade-offs. In the case of sand casting, however, these trade-offs are minimal compared to the benefits. Let’s examine some of those limitations:

Poor surface finish

Poor sand quality and process deviations can sometimes result in a poor surface finish in sand castings. Any breakdown in the sand mould can lead to a rough surface. For products needing a high-quality surface finish without extensive post-processing, die casting and investment casting are often preferred, but sand casting can also produce refined finishes with the right sand and processes.

Using high-quality, finer sand provides a much better surface finish, but it increases the cost of the process. Proper ramming or packing of sand particles also helps to improve the surface finish. To rectify surface defects such as an overly rough finish, sand castings usually undergo machining operations like turning, grinding and shot blasting.

Loose control of cooling rates

While cooling rates can be controlled more effectively in many metal fabrication processes, the same cannot be said for sand casting. Sand, being an insulator, exacerbates the challenges related to the cooling stage. The cooling stage is considerably prolonged in sand casting, impacting lead times and production rates.

Some variation in microstructure anisotropy can occur due to varying cooling rates. Anisotropy refers to the changes in mechanical properties resulting from alterations in the grain orientation of the material.

Forming internal cavities can be difficult

The sand casting method requires the placement of cores in the mould cavity to form internal cavities. For instance, when manufacturing an engine block, empty cavities for the engine cylinders need to be created during the casting process.

Creating internal chambers, holes, or spaces within the mould cavity is challenging as they must be positioned correctly and adequately supported to withstand the casting process. The more complex these cavities get, the more challenges need to be overcome.

Skilled labour is required if the process is not automated

Automated processes can be costly. However, without automation, the process relies on skilled sand casting experts to craft patterns, moulds, and oversee the process to ensure a high-quality product. Without skilled labour, the outcomes may fall significantly below acceptable standards, resulting in reputational and material losses.

Sand disposal can be a challenge

Foundries recycle moulding sand as much as possible, but after a specific number of cycles, it is no longer fit for reuse. However, waste sand from foundries is a harmful contaminant that can lead to environmental issues.

Construction is one of the sectors where waste foundry sand is now being diverted for disposal. It is being used as a substitute for fine aggregate (sand) in concrete. This practice not only addresses the issue of sand disposal but also lowers the cost and carbon emissions linked to concrete production.

But apart from this, most of the waste foundry sand ends up in a landfill, which is certainly not ideal. The options for recycling casting sand are limited.

Conclusion

Despite traditional sand casting being an ancient process, it has undergone remarkable refinements, making it highly relevant and useful in today’s manufacturing landscape. Its popularity is partly attributed to its versatility across various metal types and product sizes, and partly to the cost efficiency compared to other casting processes.

Ongoing innovations in material science and process automation further expand sand casting’s significance in industries ranging from automotive to construction. As industries evolve, sand casting will persist in shaping the industrial landscape, blending tradition and innovation in metalworking techniques.

The post Sand Casting – Process, Sand Properties, Pros & Cons appeared first on Fractory.

In the modern business landscape, sustainability is no longer a mere buzzword; it’s a strategic imperative. Companies increasingly recognise the need to operate sustainably, not just within their own operations but also in their procurement practices.

Sustainable procurement, or green procurement, incorporates environmental, social and governance (ESG) factors into the decision-making process for acquiring goods and services. This approach ensures that business needs are met while minimising negative impacts on the planet and society.

This comprehensive guide aims to provide you with the knowledge necessary to implement sustainable procurement practices within your supply chains and organisation. We will explore core concepts, highlight benefits and offer practical examples to help you initiate or enhance your own sustainable supply chain and procurement journey.

Understanding Sustainable Procurement

Traditionally, procurement decisions have focused primarily on cost, quality and lead times. Sustainable procurement broadens this perspective by considering the entire life cycle of a product or service, which includes:

• Environmental impact: Assessing resource extraction, energy consumption, greenhouse gas emissions, waste generation, and end-of-life disposal.

• Social impact: Evaluating labour practices, working conditions, human rights, diversity, and community development.

• Governance: Ensuring transparency, ethical sourcing, anti-bribery measures, and regulatory compliance.

By integrating these factors alongside cost and quality, sustainable procurement fosters competitive advantage and a more responsible and holistic approach to business.

The ISO 20400 standard provides comprehensive guidelines for integrating sustainability into procurement processes, making it a valuable resource for businesses starting on this path.

The Rise of the Triple Bottom Line

The concept of sustainable supply chains and procurement is closely linked to the triple bottom line (TBL), which expands the traditional focus on financial performance to include social and environmental responsibility. This means considering the impact of your business on:

• People: Employees, suppliers and the communities where you operate.

• Planet: The environment and its resources.

• Profit: The financial sustainability of your organisation.

Sustainable procurement acknowledges that these three aspects are interconnected. By making responsible choices, businesses can contribute to a healthier planet, a more just society, and a stronger bottom line.

Why Is Sustainable Procurement Important?

There are numerous compelling reasons to embrace sustainable procurement. Here are some key benefits:

Economic benefits

• Cost reduction: Implementing life-cycle costing and improving resource efficiency can lead to significant cost savings.

• Market access: Increasing demand for sustainable products opens new market opportunities. However, it’s important to integrate target costing strategies early, as this helps ensure that products are not only sustainable and technically sound but also competitively priced.

Environmental benefits

• Carbon footprint reduction: By choosing environmentally friendly products and suppliers, businesses can minimise their carbon footprint.

• Resource conservation: Sustainable procurement helps conserve natural resources and mitigate climate change impacts.

Social benefits

• Ethical labour practices: Supporting suppliers who adhere to fair labour practices ensures better wages and working conditions.

• Community development: Investing in local communities promotes overall societal well-being.

Risk mitigation

• Legal and reputational risk reduction: Adopting sustainable practices reduces exposure to risks associated with non-compliance and unethical behaviour.

Enhanced brand image

• Commitment to sustainability: Demonstrating a commitment to sustainability can attract environmentally conscious customers and investors.

Getting Started

Implementing sustainable procurement practices requires a strategic approach. Here are key steps to take:

Align with your ESG goals: Define your organisation’s sustainability objectives and identify areas where procurement can contribute. This alignment ensures that procurement efforts are in sync with broader organisational goals, including early design decisions affecting the sustainability of the product down the line.

Develop a sustainable procurement policy: Outline your commitment to supply chain sustainability and establish clear guidelines for your supply chain management and procurement team. A well-defined policy serves as a foundation for consistent and effective practices.

Integrate sustainability into your procurement processes: Factor in environmental, social, and governance considerations alongside traditional criteria like cost and quality. This integration ensures a balanced approach to decision-making.

Build supplier relationships: Work collaboratively with suppliers to identify and implement sustainable practices throughout the supply chain. Strong partnerships with suppliers can drive innovation and continuous improvement in supply chains.

Track and measure progress: Monitor your performance and continuously improve your sustainable supply chain management and procurement strategies. Employing cost-value engineering approaches can help in regularly evaluating the cost-effectiveness of sustainable choices, ensuring that you’re achieving value without sacrificing environmental goals.

Category Examples: Putting Sustainability into Action

To illustrate how sustainable procurement can be applied, let’s explore specific categories:

Single-Use Plastics (SUP)

Shift away from disposable plastics towards reusable alternatives such as metal straws or durable tableware. This reduces waste and environmental impact.

IT Hardware

Consider the energy costs, usage, consumption and end-of-life disposal when selecting IT equipment. Opt for energy-efficient models and establish e-waste recycling programmes.

Engineering Materials

Prioritise sustainable materials and suppliers in engineering projects. This could include using recycled metals or opting for metals with a smaller footprint, sourcing materials from suppliers who adhere to environmental standards, and selecting low-carbon concrete alternatives. By focusing on sustainable materials, engineering projects can significantly reduce their environmental footprint and support responsible mining and manufacturing practices.

Cacao

Partner with suppliers committed to sustainable farming practices and fair labour conditions. This ensures ethical and sustainable sourcing and supports community development.

These examples are just a starting point and the possibilities for sustainable procurement are vast.

Building a Sustainable and Green Supply Chain

Sustainable supply chains are essential for businesses committed to responsible supply chain operations and procurement practices. Here are some strategies for building and maintaining a sustainable supply chain:

Conduct Supplier Assessments

Regularly evaluate suppliers based on their sustainability practices. This includes reviewing their environmental impact, their child labour and fair labor practices, and governance of their environmental standards. Supplier assessments help ensure that your partners align with your sustainability goals.

Promote Supplier Development

Work with suppliers to improve their sustainability practices. This could involve providing training, resources, or incentives to supply chain transparency to help them adopt more sustainable methods. Collaborative efforts can lead to significant improvements across the supply chain.

Encourage Transparency and Traceability

Ensure that your supply chain is transparent and traceable. This means knowing the origins of the raw materials and products you source and understanding the practices of your suppliers at every level. Transparency builds trust and accountability.

Implement Sustainable Logistics

Optimise your logistics to reduce environmental impact. This could involve consolidating shipments, using eco-friendly transportation methods, or adopting efficient route planning. Sustainable logistics can significantly reduce your carbon footprint and also, transportation costs.

Foster Innovation and Continuous Improvement

Encourage innovation within your supply chain to find new solutions to sustainability challenges. Continuous improvement should be a core principle, driving ongoing efforts to enhance supplier sustainability performance. Effective tail spend management can also support sustainability goals by reducing unnecessary transactions.

Reducing Carbon Emissions Through Sustainable Procurement

Reducing carbon emissions is a critical aspect of sustainable procurement. Here are some strategies to help minimise your organisation or supply network’s carbon footprint:

Prioritise low-carbon suppliers: Select suppliers who are committed to reducing their carbon emissions. This can include suppliers who use renewable energy, employ energy-efficient practices, or have carbon offset programmes.

Implement green technologies: Adopt green technologies in your operations and encourage suppliers to do the same. This includes using energy-efficient machinery, investing in renewable energy sources, such as innovative solar balcony railings, and implementing carbon capture technologies.

Optimise transportation: Reduce emissions associated with transportation by optimising logistics, consolidating shipments, reducing waste and choosing eco-friendly transport options. Electric or hybrid vehicles and efficient route planning can significantly lower your carbon footprint. Integrating Design for Supply Chain principles early on in your product development process can help ensure that sustainability is embedded into the product early on, from materials selection to logistics.

Encourage product life cycle management: Consider the entire life cycle of products, from design and production to disposal. Promote the use of materials and processes that have a lower environmental impact and ensure proper recycling and disposal methods.

Set carbon reduction targets: Establish clear carbon reduction targets and track progress regularly. Transparent reporting on carbon emissions helps hold your organisation accountable and demonstrates your commitment to sustainability.

Conclusion: The Future of Procurement Is Sustainable

Sustainable procurement is not a trend; it’s the future of responsible business practices. We can already see this by looking at the steps taken by the EU: the new EU Supply Chain Law holds companies directly responsible for any environmental harm and human rights violations that occur along their value chain. Thus, by integrating sustainability into your procurement process, you can ensure long-term success for your organisation while contributing to a more sustainable world.

Taking Action:

Learn More About CO2 Analytics

CO2 analytics tools help companies track their carbon footprint associated with spending. Understanding your carbon footprint is crucial for making informed decisions.

Explore Solutions for Sustainability and Supplier Diversity

Discover resources to enhance your own sustainable supply and procurement journey. Engaging with diverse suppliers can drive innovation and support broader sustainability goals.

Embrace Sustainable Procurement Now

The time to act is now. By embracing sustainable procurement, you make a positive impact on your business, society and the planet. Sustainable procurement is a journey and each step forward contributes to a more sustainable future.

According to our sustainable manufacturing survey, businesses across various sectors are increasingly prioritising carbon emissions reductions, with many adopting transparent reporting to align with global sustainability goals.

By incorporating these practices, businesses can lead the way in fostering a more sustainable and ethical global economy. As you embark on this journey, remember that sustainable procurement is not just about compliance; it’s about creating value for all stakeholders and ensuring long-term success.

The post Sustainable Procurement 101: A Comprehensive Guide for Businesses appeared first on Fractory.

Businesses and projects of all sizes face various risks, and being prepared for them is crucial to meeting the initially set target cost and, ultimately, for business success. The risk assessment matrix is a powerful tool that helps to navigate these uncertainties.

What Is a Risk Assessment Matrix?

A Risk Assessment Matrix, also known as a Risk Matrix or Risk Control Matrix, is a visual tool widely used in project management and various other fields. It acts as a grid-like chart to assess potential project risks based on two key criteria:

• Risk probability (likelihood): How likely is the risk to happen? (very likely, likely, possible, unlikely, very unlikely)

• Risk impact (severity): How bad could the consequences be? (very high, high, moderate, low, very low)

Plotting each identified risk on the matrix, based on its probability and impact, provides a clear view of potential threats. This allows to understand the different types of risks, focus on the ones that demand the most attention during project planning, determine relevant actions for each identified risk to mitigate or eliminate its impact, as well as visualise the relative importance of different risks, facilitating informed decision-making.

What Are the Types of Risk Assessment Matrix?

While the traditional risk matrix focuses on likelihood and impact, there are different types of risk assessments that can be used alongside the matrix or independently. The best type of matrix for a project depends on its complexity, the level of detail required and the resources available.

1. Qualitative Risk Assessment: This is the most common type used with risk assessment matrices. It focuses on qualitative descriptions of likelihood and impact, such as “high,” “medium,” or “low.” It is a good starting point for understanding potential risks and prioritising them based on severity.

   Examples of use: Software development projects with a focus on identifying major functional or integration risks, initial risk assessment for a construction project.

2. Quantitative Risk Assessment: This type uses numerical values to assess both likelihood and impact. It involves data analysis, historical data, or even statistical models to assign more precise probabilities and impact scores. This approach is more detailed but requires more data and expertise.

   Examples of use: Large-scale infrastructure projects (bridges, tunnels), financial investments with potential market volatility, projects with strict safety regulations (e.g., chemical plants).

3. Generic Risk Assessment: This type focuses on identifying and assessing common risks that might be encountered across different projects or industries. It is a good starting point to get a general overview of potential issues but may not capture project-specific risks.

   Examples of use: Risk assessment for IT infrastructure upgrades in a company, initial risk identification for product development projects within a specific industry (e.g., medical devices).

4. Site-Specific Risk Assessment: This type focuses on identifying and assessing risks specific to a particular location, environment, or situation. It considers factors unique to that location and its potential impact on the project or business.

   Examples of use: Building a wind farm in a high-wind zone, a construction project in a region with frequent earthquakes, restoration project on a historical building.

5. Dynamic Risk Assessment: This type recognises that risks are not static. It is an ongoing process that monitors and updates the risk assessment as the project progresses and supplier relationships or business circumstances change. New risks might emerge, and the likelihood or impact of existing risks might evolve.

   Examples of use: Research and development projects with unknown outcomes, construction projects with phased deliveries and potential design changes, large-scale software development projects with ongoing feature updates.

Relationship to Risk Matrix: The risk matrix can be used with any of these types of assessments. Qualitative assessments are commonly used with the matrix due to their simplicity. Quantitative scores, if available, can also be incorporated into the matrix for a more precise evaluation. The matrix itself does not dictate the type of assessment but rather serves as a visual tool to present the results regardless of the method used to evaluate risks.

What Are the Common Risk Rating Scales?

Risk matrices typically use a square grid with scales for probability and impact. Common matrix sizes include:

• 3×3 Matrix (simple and efficient): This is the most basic and widely used format. It is a good choice for projects with a manageable number of risks or for projects where a quick and clear overview of major risk categories is needed.

• 4×4 Matrix (balancing detail and simplicity): Compared to a 3×3 matrix, this grid provides a more detailed view of risks by offering additional categories for both likelihood and impact. This allows for capturing a wider range of risks and their severity levels, making it well-suited for projects of moderate complexity.

• 5×5 Matrix (highly detailed and precise): This grid provides the most detailed risk assessment. It is best suited for complex projects with many potential risks and a need for precise risk assessment.

Key Differences: Risk matrices differ in various ways. Here’s the breakdown:

Choosing the right grid: The choice of grid size depends on various factors including the project’s complexity and the desired level of detail in evaluating risks. Here are the key factors to consider:

How Does a Risk Assessment Matrix Work?

1. Making a Risk Assessment Matrix

Risk matrix can be prepared as per the following main steps:

1. Pick your tools: Choose how to create your matrix (spreadsheet, project management software, pre-made matrix template).

2. Brainstorm risks: Identify all potential project roadblocks, internal and external.

3. Select risk approach: Pick a method (qualitative, quantitative, etc.) that fits your project’s complexity and resources. This also includes choosing the grid size (3×3, 4×4, or 5×5) for your matrix.

4. Rate risk impact & probability: Estimate how likely each risk is to occur (probability) and how badly it could impact your project (impact).

5. Plot & prioritise: Place each risk on the matrix based on its likelihood and impact. Focus on addressing high-probability, high-impact risks first.

2. Calculating Risk in the Matrix

There are two common methods used to calculate risk in a risk matrix:

1. Qualitative approach (simple ranking): This approach is favoured for its ease and speed. It uses descriptive terms like “high,” “medium,” or “low” for both likelihood and impact. The risk rating is then determined by combining these categories.

   Example: A risk with a “high” likelihood and “medium” impact might be ranked as “high-medium” or simply “high,” indicating a significant concern requiring attention.

2. Quantitative approach: This method offers more precision by assigning numerical values to both likelihood and impact. These values are then multiplied to generate a risk score.

   Example: Likelihood: “high” (assigned a value of 4), Impact: “severe” (assigned a value of 5). The risk score would be 4 x 5 = 20. This allows for an objective ranking of risks, with higher scores indicating greater threats. 

3. Using the Matrix

Once you have a populated risk matrix, you can use it to proactively manage project risks. Here are some key steps:

1. Prioritise: Focus on high-risk areas (red zones) in the matrix. These require immediate attention. Develop plans for moderate risks and document even low ones.

2. Develop strategies: Create plans to manage risks. This could involve:

   • Avoidance: Eliminate the risk entirely (e.g., find multiple material suppliers).

   • Mitigation: Reduce the risk’s impact (e.g., implement stricter quality control procedures).

   • Transference: Shift the risk to someone else (e.g., purchase insurance to cover delays caused by labour strikes).

   • Acceptance: Live with the risk if the consequences are manageable (e.g., schedule buffer for bad weather).

3. Make a plan: Create a detailed risk management plan outlining actions, responsible parties, resources, and timelines for addressing each risk.

4. Communicate: Share the matrix with stakeholders for informed decision-making.

5. Update regularly: Review the matrix as your project progresses. New information may require updates to the matrix and the risk management plans.

By following these steps, your risk matrix becomes a dynamic tool for proactive risk management throughout your project life cycle. It’s particularly effective when integrated into broader procurement transformation, allowing for a more structured approach.

How to Maintain a Risk Assessment Matrix?

A powerful matrix needs ongoing care to stay effective, this involves:

• Train & review: Training teams on risk assessment and holding regular reviews (monthly is a good start) to update risks, ratings and controls based on project progress and new information.

• Team & stakeholder input: Encourageing team member input for a comprehensive risk view, and keep stakeholders informed about risks and mitigation plans.

• Communication & process: Maintain clear communication channels for risks with internal and external stakeholders and consider process improvements to reduce them.

• Proactive measures: Design processes, products, or services with risk mitigation in mind, have contingency plans, and learn from industry best practices.

• Lessons learned: After project completion, analyse past data to identify common risks and refine your risk assessment process for future projects.

By following these practices, risk matrix remains a collaborative tool that continuously improves project outcomes.

Example of a Risk Assessment Matrix

The following is an example of a basic 4×4 risk matrix, focusing on a construction project. This format can be adapted to specific needs regarding project complexity.

Risk rating: The risk rating is determined by the intersection of the risk probability and impact. Here, a 4×4 risk matrix example is used, resulting in 16 possible risk ratings (e.g. very likely – high = very high).

Control measures: The final column outlines some possible control measures to mitigate the identified risks. These can be further elaborated upon in a risk management plan.

What Tools Are Available to Create a Risk Assessment Matrix?

There are many ways to create a risk matrix. Popular options include:

• Spreadsheets (Excel, Google Sheets): Ideal for customisation and control over layout, categories and rating scales. Great for smaller projects or when a specific format is needed.

• Project management software (Asana, Trello): Streamlines risk assessment within your existing workflow and fosters collaboration with built-in features and familiar interfaces.

• Dedicated risk management software: Offers advanced features like risk scoring and trend analysis for complex projects or high-risk environments. Perfect for in-depth analysis and comprehensive risk management plans.

• Online templates: Free or paid matrix templates provide a quick starting point with pre-defined categories for basic projects, saving time on initial setup.

To determine the suitable option, there are some key features to consider in the software selection process:

• Pre-built risk register templates.

• Integration of risk register for centralised risk data storage.

• Ability to define and customise risk matrix categories.

• Options for assigning probability and impact ratings.

• Automated risk score calculations (if using a quantitative approach).

• Sorting and filtering functionalities to prioritise risks.

• Risk owner assignment for clear accountability.

• Risk mitigation progress tracking.

• Risk reporting.

• Visualisation tools for charts and heatmaps to represent risk data.

Overall, choosing the right method depends on project complexity, team size and desired features. The key is a clear, concise and easy-to-understand matrix.

What Are the Benefits & Limitations of Using a Risk Assessment Matrix?

The risk matrix offers valuable tools for project management, but it is important to understand its strengths and limitations.

Benefits:

• Proactive risk management: The matrix allows for early identification and mitigation of risks, minimising their impact on the project.

• Prioritisation and focus: By highlighting critical risks (high probability and impact), the matrix helps focus resources and attention on the most important issues.

• Improved decision-making: A clear and visual representation of risks allows for better-informed decisions regarding resource allocation, project planning and overall management strategies.

• Enhanced communication and collaboration: The matrix provides a standardised and concise way to communicate project risks to all stakeholders, fostering transparency and collaboration.

Limitations:

• Subjectivity and uncertainty: Assigning risk probability and impact involves some degree of subjectivity, and unforeseen events can always emerge.

• Data dependence: The effectiveness of the matrix relies on the quality of the data used. Inaccurate or incomplete information can lead to misleading results.

• Oversimplification: Complexities of real-world risks may not be fully captured in a matrix. Use it as a guide, not a definitive answer.

• Time and effort: Creating and maintaining the matrix requires time and effort.

• Over-reliance: The matrix should complement sound project management practices and continuous monitoring, not replace them.

Conclusion

The risk assessment matrix is a powerful tool for professionals across various fields, including engineering, construction, procurement, financial, and IT among many others. It offers a systematic approach to managing risks, ultimately boosting your project’s success rate and avoiding costly surprises. This is not a one-time activity, it is an ongoing process, requiring continuous monitoring and adaptation throughout the project lifecycle.

Common FAQs About the Risk Assessment Matrix

1. Is a risk matrix complex to create?

Creating a basic risk matrix is fairly straightforward. You can use a simple Excel sheet with a grid and defined scales for likelihood and impact. More complex projects might benefit from dedicated risk management software with additional features.

2. What if I can not decide between two likelihood or impact scores?

Some subjectivity in scoring is acceptable. When in doubt, prioritise caution and select the higher rating. This approach safeguards against underestimating potential risks. You can always refine your assessments as you gather more information.

3. Who should be involved in creating and maintaining the risk matrix?

Involving a variety of stakeholders in the risk assessment process is beneficial. This could include project managers, team members, subject matter experts, and even clients. Each person brings a unique perspective that can help to identify potential risks and develop effective mitigation strategies.

4. What are some alternatives to the risk matrix?

While the risk matrix is a popular tool, there are other risk assessment methods:

• FMEA (Failure Mode and Effect Analysis): The FMEA method focuses on identifying potential failure modes in a system or process.

• What-If scenario planning: This involves brainstorming potential negative outcomes and considering mitigation strategies.

• Delphi technique: This method gathers expert opinions anonymously to assess risks and their impact.

• SWOT Analysis (Strengths, Weaknesses, Opportunities, Threats): This goes beyond threats, considering your project’s strengths, weaknesses, and opportunities, providing a broader perspective to inform risk management strategies and leverage opportunities to mitigate threats.

The best approach may involve combining the risk matrix with other techniques for a more comprehensive understanding of project risks.

5. Can I use a risk matrix for anything other than projects?

Absolutely, risk matrices are valuable tools in various contexts, including:

• Product development: Identify potential issues that could affect product launch or performance.

• Business decisions: Assess risks associated with new market ventures or strategic initiatives.

• Personal finance: Evaluate potential risks to your financial goals, such as job loss or unexpected medical bills.

6. Where can I find more information about risk matrices?

Many resources are available online and in libraries. Project management institutes and professional risk management organisations often offer resources and training materials.

By addressing these FAQs and effectively using a risk matrix, you can significantly enhance your project risk management skills and increase chances of project success.

The post Risk Assessment Matrix – What Is It & How It Works appeared first on Fractory.

In this article, we’ll look into centrifugal casting process to understand its operation in detail, its types, and the benefits it offers.

What Is Centrifugal Casting?

Centrifugal casting is a metal casting process that uses a spinning die to produce cylindrical products like pipes and tubes. During this process, molten metal is poured into a spinning die. As the metal flows into the spinning die, centrifugal force distributes it uniformly along the inner diameter of the die.

The thickness of the casting can be accurately controlled by regulating the amount of metal poured into the cylinder. The liquid metal starts cooling and solidifying from the outside surface in contact with the cylinder.

While cylinders can be cast through other methods, they would have limitations on size, tolerances, seam strength and corrosion resistance. The formation of internal cavities would require cores and the final part may exhibit issues such as gas porosity, oxides and non-metallic inclusions.

Centrifugal casting, on the other hand, has no limitations on the length of the finished part. It allows the casting of very long parts with remarkable accuracy and consistency. Most machines can produce pipes up to 15 meters (49 ft) in length with a diameter of up to 6 meters (20 ft). The wall thickness can vary from 2.5 mm (0.1 in) to 125 mm (~5 in).

The process works best for thin-walled cylinders but it can also be used for thick-walled applications such as gear blanks, ball bearings, railway carriage wheels, and more. Centrifugal casting can also produce non-circular shapes with a near-constant radius.

Multi-layer casting is another unique feature of centrifugal casting. In this casting technique, two dissimilar materials can be combined to form a multi-layer centrifugal casting. This finds many applications in several industries. For example, steel pipes can be coated on the inside or outside with concrete to enhance their corrosion resistance and compressive strength.

Common applications of the centrifugal casting process are in piping, aerospace, automotive and military sectors. Some common products made using this process include engine cylinder liners, jet compressor cases, metal pipes, railway carriage wheels, bearings and many other tubular parts in high-reliability applications.

Centrifugal Casting Process

Centrifugal casting is a fairly straightforward process. Most often, the process is used to create standard-sized products rather than specific ones. Standardisation allows the process to take advantage of economies of scale and reduce part costs.

Let’s explore a typical centrifugal casting process, its stages and their significance. The four stages are as follows:

1. Mould preparation

2. Pouring of molten metal

3. Directional solidification

4. Removal and finishing operations

Centrifugal Casting Process

1. Mould Preparation

The mould preparation begins with cleaning the die’s inner surface to remove contaminants and debris from previous use. Once it is clean, the motors responsible for spinning the die are powered up.

The amount of force applied to the molten metal is proportional to the die’s diameter and spinning RPM. Typically, a die has a rotational speed between 300 and 3000 RPM. The centrifugal force produced by these high speeds can reach up to 100 times the force of gravity.

Then, it is time for preheating and applying a ceramic slurry to the inner surface of the die. The heat dries and cures the ceramic slurry, ensuring that the refractory lining adheres to the die’s surface.

The ceramic slurry is necessary to protect the die and facilitate the removal of the casting upon solidification. An ideal slurry also provides a smoother surface finish for the part.

2. Pouring of Molten Metal

The metal is melted in an external furnace and poured into the pouring basin of the casting machine using a ladle. The pouring basin then transfers the metal to the centre of the die through a spout. The high centrifugal forces ensure that the final product is free of cavities or gas pockets.

The centrifugal force also separates the low and high-density components in the molten metal. All the impurities float towards the inner diameter of the molten metal due to their lower densities. This results in an increased density of the molten metal at the outer diameter compared to the inner diameter.

3. Directional Solidification

The metal casting rotates continuously during the rapid cooling stage until its temperature is below the transition range. Cooling in centrifugal casting begins from the outside diameter towards the inside diameter. This type of controlled solidification in castings is also known as directional solidification.

Directional solidification offers advantages such as improved grain structure, lower concentration of impurities and the development of beneficial microstructures. Solidification shrinkage always occurs at the inner wall of the finished product in centrifugal casting.

4. Removal and Finishing Operations

Once solidification is complete, the casting is removed from the die using extraction equipment if no heat treatment is needed. In some cases, the casting is subjected to annealing before the steel mould is removed.

It is then sent for finishing operations. The impurities and lighter material that floated inward during the second stage are now machined, leaving a strong, defect-free part with excellent mechanical properties. The outside is shot blasted to remove any traces of the refractory material.

Visual and dimensional inspections are also carried out at this stage.

Types of Centrifugal Casting

Centrifugal casting processes can be classified in different ways. One method is based on the nature of the casting process, where they are divided into true centrifugal casting, semi-centrifugal casting and centrifuging processes. A second, more common method is to classify them based on the die’s orientation, i.e., horizontal and vertical centrifugal casting processes.

The processes between the two classification methods can overlap. For instance, a true centrifugal casting may involve either a horizontal or vertical centrifugal casting process.

Classification Based on the Nature of the Process

Animation of Centrifugal Casting Types

True Centrifugal Casting

The true centrifugal casting process is the most popular type of centrifugal casting process. This is the same process described in the previous section. Unlike other processes, this method does not involve a gating system. The material is poured directly into the cylindrical mold, where it contacts the mould’s internal surface and spreads uniformly.

Semi-Centrifugal Casting Method

The semi-centrifugal casting method is similar to the true centrifugal casting process, except that the former creates solid castings, unlike the latter process which produces only tubular shapes. It handles the production of solid components such as spokes, gear blanks and pulleys.

The material away from the rotational axis is denser compared to that around the axis. Impurities, due to their low density, also accumulate around the axis. After solidification, the material around the axis is machined away to make room for the axis on which the produced component will spin.

Semi-centrifugal casting provides us with a product that has excellent mechanical properties and is free of impurities.

Centrifuge Casting

Centrifuging is a unique form of centrifugal casting method that uses centrifugal forces to fill conventional moulds instead of applied pressure. In this process, we use a rotating mould with a central sprue at the axis. The sprue channels the molten material into the rotating mould as it spins.

The centrifugal force from the rotations pushes the molten metal outward and into the cavities spread along the circumference. This process includes all the components of the gating system, such as sprue, runners, gates and risers.

The spinning motion of the die pushes the material into the die until complete distribution and solidification occur. The centrifuging process is used for small-sized products such as jewellery, sleeves and bushings.

Classification Based on Die Orientation

When designing a die for centrifugal casting, we can choose to align it either vertically or horizontally. Each orientation has its benefits and limitations:

Horizontal Centrifugal Casting

Horizontal centrifugal casting refers to the casting process in which the mould’s spin axis is parallel to the ground. The horizontal axis arrangement enables the production of castings with a very high length-to-diameter ratio. Horizontal centrifugal casting is a cost-effective method that delivers high-quality results.

Some common products made using the horizontal centrifugal process include ductile iron pipes, reformer tubes, furnace rolls, sleeves and roller shells.

Vertical Centrifugal Casting

In vertical centrifugal casting, the mould spins along the vertical axis, perpendicular to the ground. This technique is more suitable for products with a short length-to-diameter ratio. Typically, the length should be less than twice the product’s width for optimal results in vertical centrifugal casting.

The effect of gravity needs to be accounted for in vertical centrifugal castings, as it can lead to distortion in the absence of sufficient centrifugal force.

Some examples of products made with this manufacturing process include ball bearings, gear blanks and pulleys.

Advantages of Centrifugal Casting

Centrifugal casting is a special type of casting process that offers unique advantages compared to other casting processes:

• Unrivalled rotational symmetry in parts

• Fine-grained structure

• Ability to seamlessly integrate two materials

• Can work with a variety of materials besides metals, such as glass and concrete

• Eliminates cores and gating system

• Lower manufacturing costs and reduced machining requirements

Limitations of Centrifugal Casting

Each manufacturing process has its limitations, centrifugal casting is no different:

• Restrictions on complex shapes: Centrifugal casting is limited to producing cylindrical castings and, to some extent, other shapes. Even within cylindrical castings, the complexity achievable through this process is restricted. For applications needing more flexibility in shape or size, other methods, such as sand casting is often chosen, offering adaptability across a broad range of geometries and product sizes.

• Inaccuracies in the inner surface diameter are fairly common. However, it is possible to generate net or near-net shapes with the right controls.

• The process requires a high initial investment. However, similar to die casting, it boasts low per-part costs, making it cost-effective in mass production scenarios.

• Parts with small inside diameters are difficult to cast.

• Operational safety can be a concern with this process because the die operates at high rotational speeds along with other rotating and moving parts.

• The centrifugal process is not particularly effective for small-sized products.

The post Centrifugal Casting – Working Principle, Types & More appeared first on Fractory.

What Is Target Costing?

Target costing strategies ensure that cost management is embedded into the design process from the start. Unlike traditional costing approaches that determine costs after the design phase, target costing begins with the end price in mind. This involves setting a target selling price based on market research and desired profit margins, then working backward to determine the maximum allowable cost that will still enable the desired price and top profit margin.

Formula for Target Costing:

Target Cost = Market Price – Desired Profit Margin

This formula helps businesses align their product design and production costs with the target pricing strategy, ensuring that the final product meets the competitive price expectations and desired profit margins. By setting a target cost early, companies can avoid costly design changes and better manage their production costs throughout the product development cycle.

Target Costing in Engineered Solutions

For engineered solutions, target costing involves a precise focus on balancing cost, functionality, and quality. The target costing process ensures that the final product or service used meets both customer expectations and financial objectives. Here’s how target costing can be applied to engineered products:

Steps in Target Costing for Engineered Products

1. Market Research: Begin by conducting thorough market research to determine the competitive market price and the amount customers are willing to pay for the proposed product. This research helps establish a realistic target selling price that aligns with market conditions and customer expectations.

2. Cost Goal Setting: Using the target selling price and desired profit margin, calculate the maximum cost that the product can afford. This maximum cost serves as a benchmark for design and manufacturing decisions, ensuring alignment with the target pricing strategy and overall profitability goals.

3. Design Optimisation: Engineers must focus on optimising the product design from concept generation to final delivery to meet the target cost without compromising on performance or quality. This might involve Design to Cost (DTC) and value engineering techniques to identify cost-saving opportunities, such as selecting cost-effective materials or simplifying and fool-proofing the design to reduce production costs and errors.

4. Supplier Collaboration: Effective collaboration with suppliers is crucial for achieving the target costs for components and materials. By working closely with suppliers, companies can negotiate better terms, identify cost-saving opportunities, and ensure that components meet both quality and cost requirements.

5. Continuous Monitoring: Throughout the design and development cycle, it is essential to monitor costs regularly to ensure that the project remains within the target cost. This involves tracking expenses, evaluating cost-saving measures, and making adjustments as needed to stay aligned with the final target cost. An often-overlooked area in cost control is tail spend – those low-value, one-off purchases that collectively impact budgets.

Incorporating Target Costing into Product Development

Integrating the target price into the product development cycle involves several key considerations:

1. Design Phase: During the design phase, target costing requires engineers to balance technical requirements with cost constraints. This may involve iterative design adjustments to ensure that the product meets both performance and cost objectives.

2. Value Analysis and Value Engineering: Implementing value analysis and value engineering techniques can help identify cost-saving opportunities and optimise product design. These approaches focus on improving the value of the product by enhancing functionality while reducing costs.

3. Life Cycle Costing: Consider life cycle costing to evaluate the total cost of ownership, including initial production costs, maintenance, and disposal costs. This comprehensive approach helps in setting realistic target costs and ensuring long-term profitability.

4. External Factors: Be aware of external factors such as market changes, regulatory requirements, and supply chain disruptions that can impact the target cost. Proactive cost planning and flexibility in design can help mitigate these risks.

Case Study: Fractory’s Role in Engineered Solutions and Target Cost Contracts

Fractory’s advanced digital manufacturing platform provides customers with a valuable tool for managing target costing in engineered solutions and contracts. By leveraging Fractory’s capabilities and expertise, companies can streamline cost management and achieve their target pricing goals more effectively.

Case Study: AIE’s Success with Fractory

Advanced Industrial Engineering, an industrial machinery manufacturer, faced challenges meeting target costs for a bespoke production line project. They required a solution to manage production costs efficiently and align the price of their offering with customer expectations.

Solution:

AIE adopted Fractory’s platform to enhance their target costing process. Fractory offered several key benefits:

1. Real-Time Cost Analysis: Fractory’s instant quoting system enabled AIE to quickly assess the cost implications of design changes. This real-time Design for Manufacturing (DFM) feedback facilitated timely adjustments to stay within the target cost.

2. Optimised Production Processes: Fractory’s account managers, who are experienced mechanical engineers, helped AIE select the most cost-effective production methods and materials. They considered factors such as tolerances, material availability, and part quantities to ensure alignment with target pricing strategies while meeting the expected lead time. This approach delivered high-quality results while keeping costs in check.

3. Enhanced Supplier Selection & Communication: Fractory’s expertise in matching projects with specialised manufacturers ensures that each step of the project is handled by the most qualified and cost-efficient supplier. In the case of AIE, the project was split between three manufacturers: one for laser cutting and bending, another one for welding, and a third for powder coating. Each manufacturer focused on their area of expertise, improving cost management and product quality. Fractory acted as the sole point of contact, significantly reducing the time and complexity of managing multiple suppliers.

Outcome:

With Fractory’s support, AIE successfully achieved its target cost while streamlining their procurement process. The platform’s real-time cost analysis, optimised production processes and enhanced supplier collaboration not only helped the business to meet its target pricing objectives but also accelerated the project’s expected completion time, providing the business with a significant competitive advantage.

Case Study: Cutting Procurement Costs - Advanced Industrial Engineering

Target Costing in Contracts

Target costing can also be effectively applied to contractual agreements, known as target cost contracts. These contracts establish a target cost before the agreement is finalised, representing the expected expense for delivering the agreed-upon product or service. Here’s how target pricing and cost contracts function:

How Target Cost Contracts Work:

1. Negotiation: Before signing the contract, the contractor and client agree on a target cost based on detailed cost estimates and project requirements. This target cost becomes the pricing benchmark for the contract, setting expectations for cost management and delivery.

2. Cost Management: During the project, the contractor works to deliver the product or service within the target cost. Any cost savings realised below the target cost are often shared between the contractor and client through a predefined profit-sharing arrangement, which incentivises cost control and efficiency.

3. Adjustments: If actual costs exceed the target cost, the contractor may be responsible for covering the additional expenses, depending on the contract terms. This arrangement encourages proactive cost planning and effective cost management to avoid overruns and maintain financial performance.

Conclusion

Target costing is a crucial strategy for managing costs in engineered solutions and contractual agreements. By setting a target selling price from the beginning and working closely with suppliers, companies can ensure that the prices of their products meet both financial and market expectations.

Fractory’s cloud manufacturing solutions play a significant role in supporting target costing efforts, offering real-time cost analysis services, streamlined production processes, and enhanced supplier integration services. For procurement professionals and engineers looking to optimise their cost management and achieve their pricing goals, Fractory provides invaluable tools and insights.

Explore how Fractory can support your target costing initiatives to reduce costs and drive success in your company’s engineered solutions.

The post Target Costing: A Blueprint for Procurement Engineers appeared first on Fractory.

The undisclosed round joins the previous round led by Kvanted, and will be used to further grow in existing markets whilst preparing for a larger Series B round. The investment will be used in part to grow the UK and Scandinavian teams, enabling Fractory to meet increasing business demands across Europe. Over a dozen engineering and commercial roles will be recruited to manage an increasing number of customer projects, growing the international team to over 90.

The funding will also be used to build supplier visibility and environmental impact of manufacturing and transportation into the platform. ‘‘The data is already there, we just have to make accessing it clear and simple.’’ says Martin Vares, Fractory’s CEO.

Martin Vares, CEO & Co-Founder, Fractory:

‘‘In Fractory’s case, sustainability and efficiency go hand in hand. Efficiency for us means making use of the existing capacity and capabilities the market has to offer—sustainability is a very welcome additional benefit.

We have a lot of data—both current and historic—that can aid our customers in their pursuit of meeting the EU’s climate regulations. Tracking the environmental impact of supply chains with precision is a challenge because getting reliable data is difficult. It’s not uncommon for companies to regularly use tens or even hundreds of manufacturers, further adding to the difficulty.

We’re well positioned to tackle this problem because the data we already process for all our orders enables us to also calculate an accurate environmental footprint—this is soon to become mandatory for businesses in the manufacturing industry.

We’re able to utilise this data, share it, and ultimately help companies decrease their environmental impact.’’

Sille Pettai, Fund Manager, SmartCap:

‘‘Fractory is emerging as a promising player in the digital manufacturing sector, leveraging its advanced platform to streamline metal fabrication services.

This investment is a crucial step in our strategy to support innovative startups that are driving efficiency and growth within the manufacturing industry. Fractory’s platform enhances machine utilisation rates in factories across their supplier network by up to 80% and decreases material waste.

By backing Fractory, we are endorsing their commitment to revolutionising production processes and enhancing supply chain dynamics.’’

SmartCap Green Fund is funded by the European Union’s NextGenerationEU. The fund is focused on investments in greentech companies operating in the fields of energy, agriculture, food, transport, logistics, materials, chemicals, and the environment.

The post Fractory Funded by SmartCap Green Fund appeared first on Fractory.

But within this broad umbrella, there are two main categories: direct procurement and indirect procurement. While they both involve acquiring items a business needs, they differ significantly in what they acquire and how they are managed.

Understanding these distinctions is crucial for anyone involved in the supply chain, including engineers, as it affects everything from project costs to overall business success.

Direct Procurement

What is Direct Procurement and its role in business?

Direct procurement involves acquiring the raw materials, components and parts that are physically transformed or assembled into finished products. These are the core supplies that directly impact a company’s ability to produce and sell its offerings.

Effective direct procurement directly influences a company’s profitability and competitive advantage.

What are the common examples of Direct Procurement?

Examples of direct procurement include:

• A car manufacturer procuring various metals, tyres and engines for its vehicles.

• A clothing company buying fabric, buttons and zippers for its garments.

• A software company licencing specific software components to integrate into its own product.

• An aerospace company purchasing specialised alloys, composites and high-performance fasteners for aircraft construction.

• A medical device manufacturer directly procuring biocompatible materials, microelectronics and miniature components for their products.

What is the impact of Direct Procurement on different business factors?

Direct procurement has a significant impact on a company’s profitability and competitive advantage in several factors including the following:

• Cost savings: Negotiating favourable prices for raw materials and components directly affects production costs. Lower material costs translate to lower prices for the finished product, allowing companies to remain competitive in the market and potentially achieve higher profit margins.

• Quality control: Ensuring high-quality raw materials and components are used minimises product defects and rework which can be costly to fix. Accordingly, maintaining quality control directly influences the final product’s quality and reputation, leading to customer satisfaction and potentially reducing warranty claims.

• Supplier relationships: Building strong, reliable partnerships with direct material suppliers is crucial for securing a consistent flow of essential materials and maintaining production schedules. Delays or disruptions in the supply chain caused by unreliable suppliers can halt production and significantly impact revenue.

How is Direct Procurement managed?

When it comes to effective direct procurement management, the focus is often on three key areas:

• Strategic sourcing: Identifying and collaborating with the best suppliers who offer quality materials at competitive prices. This involves the collaboration of procurement teams with internal stakeholders like engineers to identify the best suppliers based on factors like quality, cost and reliability.

• Inventory management: Maintaining optimal stock levels of direct supplies (raw materials and components) to avoid production delays and without incurring unnecessary storage costs. This may involve company utilisation of just-in-time (JIT) inventory practices to minimise storage needs and optimise cash flow.

• Strategic suppliers relationship management: Developing strong, long-term partnerships with key suppliers for mutual benefit. Beyond price, strong supplier partnerships foster open communication to identify cost savings, improve processes and drive innovation. This might involve joint planning, early supplier involvement and shared performance metrics.

Indirect Procurement

What is Indirect Procurement and its role in business?

Indirect procurement deals with acquiring goods and services that are necessary for a company’s day-to-day operations but do not directly become part of the final product. These are often referred to as indirect spend or business expenses.

While not directly impacting the production process itself, indirect procurement significantly influences a company’s bottom line through cost optimisation.

What are the common examples of Indirect Procurement?

Examples of indirect procurement include:

• Office supplies: Paper, toner cartridges, pens and sticky notes.

• Facilities management: Cleaning, security, waste disposal, maintenance of equipment and buildings.

• Information technology (IT): Software licences, hardware purchases and IT support services.

• Marketing and advertising: Materials used for promoting a company’s products or services.

• Professional services: Consultants, lawyers, accountants and engineers.

What is the impact of Indirect Procurement on a business’s bottom line?

While not directly impacting the production activities and final product, indirect procurement significantly influences a company’s bottom line through several factors including the following:

• Cost optimisation: Indirect spend, which refers to the total expenditure on indirect goods and services, can represent a substantial portion of a company’s overall budget (15-30%). Efficient indirect spend management and finding ways to reduce spending on non-essential supplies and services, through strategies like volume discounts, tail spend optimisation, utilising multiple vendors or consolidating purchases through indirect procurement processes, can free up resources for core business activities like product development or marketing.

• Streamlined processes: Implementing standardised indirect procurement process for frequently purchased indirect goods and services can save time and reduce administrative costs associated with requisitioning, approvals and purchase orders. Streamlined processes allow employees to focus on more strategic tasks.

• Improved efficiency: Indirect procurement can impact efficiency in various areas. For example, choosing the right facilities management provider can ensure a well-maintained work environment, potentially reducing equipment downtime and improving overall operational efficiency.

How Indirect Procurement is managed differently from Direct Procurement?

The approach to indirect procurement differs from direct procurement. While direct procurement management often focuses on strategic sourcing, inventory management and key strategic supplier relationship management, indirect procurement management often focuses on cost control, streamlining processes and managing a wider range of operational suppliers.

Supplier relationships remain important, but the emphasis on indirect procurement typically shifts towards finding the most cost-effective solutions for indirect goods and services through operational suppliers rather than building long-term partnerships with strategic suppliers.

Accordingly, effective indirect procurement management mainly focuses on three major areas:

• Cost control: Collaborative forecasting by procurement teams with internal departments, like facilities, marketing or IT, to identify and source indirect needs allows for targeted cost reduction through vendor consolidation and price negotiation. It also ensures optimal inventory levels and minimises unnecessary spending on indirect goods and services.

• Processes streamlining: Indirect procurement often involves standardised procedures for purchasing frequently needed items. This may include utilising e-procurement platforms to automate routine tasks associated with indirect purchases.

• Operational suppliers relationship management: Companies may utilise a wider range of vendors for indirect goods and services compared to those used for direct procurement, hence, leveraging competition to drive down prices.

Key Differences

The following table summarises the key differences between direct and indirect2 procurement:

Best Practises

For effective direct procurement:

• Develop strong supplier relationships: Building trust and collaboration with key direct material suppliers ensures a reliable flow of high-quality materials.

• Implement strategic sourcing: Conduct thorough market research to identify the best suppliers based on factors like cost, quality and delivery times.

• Maintain optimal inventory levels: Balance having enough direct supplies to avoid production disruptions with minimising storage costs.

For efficient indirect procurement:

• Standardise processes: Implement clear procedures for requisitioning, approving and purchasing of frequently needed indirect goods and services.

• Leverage technology: Utilise procurement software to automate tasks, track spending data and identify areas for cost savings.

• Negotiate effectively: Negotiate favourable pricing and terms with vendors, especially for high-volume indirect purchases.

Real-world Examples

Tesla

Direct Procurement:

• Lithium (for batteries): A critical raw material for Tesla.

• Silicon (for semiconductors): Tesla heavily relies on semiconductors for its electric vehicles.

• Aluminium (for car bodies): Tesla uses aluminium for its lightweight car bodies.

Indirect Procurement:

• Factory equipment (e.g., robotic arms): Needed for welding and assembly operations but not directly part of the car.

• Marketing and advertising services: To promote Tesla vehicles.

• Software licences (e.g. CAD software): Used for designing and engineering Tesla products.

Boeing

Direct Procurement:

• Titanium (for aircraft structures): Provides strength and reduces weight.

• Jet engines: A crucial component of aeroplanes.

• Avionics (flight control systems): Essential for safe and efficient flight operations.

Indirect Procurement:

• Office equipment and furniture: Needed for administrative functions.

• Information technology services: To maintain Boeing’s IT infrastructure.

• Maintenance, repair and overhaul (MRO) services: For upkeep of Boeing’s aeroplanes.

Conclusion

Both direct and indirect procurement play crucial roles in a company’s success. One key difference between them is their focus. Effective direct procurement ensures a steady supply of high-quality materials for production, while efficient indirect procurement controls cost and optimises business operations.

In today’s digital age, technology plays an increasingly important role in modern procurement practises, with tools and platforms facilitating better supplier management, spend analysis, and overall process optimisation.

The post Direct vs Indirect Procurement – What’s the Difference? appeared first on Fractory.

What Is Die Casting?

Die casting is a metal casting process that uses metal dies to create metal parts. Molten metal is poured or injected into the metal dies and allowed to solidify. Once solidified, the parts are removed from the mould and put to use after minimal finishing operations.

The die casting process is primarily used for casting non-ferrous metals, such as aluminium, magnesium, zinc and their alloys, but it can also be used for other metals with comparable melting points.

Die casting is essentially the same as injection moulding, as the primary difference lies in the materials used – molten metal vs molten plastic. Additionally, die casting requires higher temperatures and pressures due to the properties of metals, and the moulds are typically made from high-strength steel to withstand these conditions, whereas injection moulding can use moulds made from a variety of materials due to the lower temperatures and pressures involved in processing plastics.

Applications of Die Casting

Die casting is widely used in various industries to produce parts such as:

• Automotive components (engine blocks, transmission cases and wheel rims)
• Consumer electronics (housing for laptops, smartphones and cameras)
• Appliances (handles, brackets and heat sinks)
• Aerospace components (aircraft parts and fittings)
• Industrial equipment (pumps, valve bodies and enclosures)

Die Casting Process

The die casting process can have different mechanics depending on the metal, application and the process employed. For instance, the molten metal could be poured via gravity or injected into the die under high pressure.

Let’s explore a typical die casting process, which involves six main stages:

1. Mould Creation

2. Mould Preparation

3. Metal Injection

4. Cooling

5. Casting Removal

6. Finishing Operations

1. Mould Creation

The mould in die casting is a metal die with an internal cavity the same shape as the product. Nowadays, CAD/CAM and CFD (Computational Fluid Dynamics) software are used to design moulds. These programs can accurately simulate the smallest details about a mould such as internal friction, temperature distribution, flow rates, heat dissipation rate and lubrication efficiency.

After successful simulations, the engineers share the drawings and specifications, such as tolerance and tonnage, with specialist toolmakers. These specialised toolmakers create the mould through CNC machining and run trials to ensure that the final product meets the specifications. In addition to the cavity, an industrial die also contains channels for metal flow, a cooling system and ejector pins.

This is one of the critical stages in die casting. A high-quality mould can eliminate many issues downstream, such as surface defects, material wastage, shrinkage, warpage and incomplete filling.

2. Mould Preparation

The mould preparation stage involves setting up the mold in a way that is most favourable to producing high-quality castings.

The mould is made up of two halves: the fixed die half, which is connected to the injection system, and the removable die half, which separates to remove the casting.

Engineers clean and heat the mould before pouring molten metal into it. They also spray the inner surfaces of the mould with lubricant or refractory material. Of course, these processes can be automated as well.

The lubricant serves multiple functions, including reducing internal friction, aiding in maintaining the die’s temperature, preventing premature solidification of the molten metal in the die, and facilitating the removal of the cast from the die once the metal has solidified.

Finally. the mould halves are closed and secured together using high pressure before pouring the metal.

3. Metal Injection

In this stage, molten metal fills the die uniformly. This action can be performed in two ways. One method is gravity die casting, where the force of gravity is utilised to fill all the internal cavities in the mould. This process involves pouring the molten metal from a ladle into a downward sprue that leads to the mould cavity.

The second method, also known as high-pressure die casting, fills the mould by injecting the molten metal into it under high pressure. The pressures can range from 100 bars (1,400 psi) to 1800 bars (26,000 psi). This method offers several advantages over gravity die casting, such as faster and better filling of the mould, the capacity to create intricate structures with thin walls, high dimensional stability, smoother surface finish and the minimisation of finishing operations downstream.

4. Cooling

Once the molten metal has completely filled the mould, the cooling stage begins. It is important to ensure a uniform and controlled cooling rate to obtain the desired microstructure in the final product.

Molten metal must be given enough time to cool to prevent surface or internal defects from forming in the part.

5. Casting Removal

Once the cast is set, the mould halves are unclamped to facilitate the removal of the casting. This may be done manually or automated using ejector pins. The ejector pins are built into the mould to safely and automatically separate the cast when the mould halves are separated.

6. Finishing Operations

Finishing operations are necessary to remove the sprue, runners and other gating system components from the casting. These components are then remelted in the furnace for reuse.

The casting may also need finishing operations, such as surface grinding and machining before it is ready for handover to the customer.

High Pressure Die Casting Process

Types of Die Casting

Die casting processes can be carried out under different conditions depending on the specifications of the process and the final part.

Among the many specialist processes in die casting, two are worth elaborating on: the hot chamber die casting and cold chamber die casting processes. Let’s have a look at both of these processes to gain a better understanding.

Hot Chamber Die Casting

The hot chamber in the hot chamber die casting process refers to an internal furnace within the casting machine. The furnace is connected to the die cavity through a feeding system known as the “gooseneck”. As the metal is melted within the casting machine itself, this process offers faster cycle times of about 20 minutes, making it a worthy contender for mass production.

The hot chamber, however, cannot reach very high temperatures. Therefore, the process is most suitable for low melting point metals such as lead alloys, zinc alloys and magnesium alloys. As the metal melts, it is forced into the die through the gooseneck by a plunger.

The plunger withdraws when the metal in the die solidifies. The mould opens and the casting is removed. Then, the mould closes once again, the plunger transfers the hot metal into the die cavity, and repeats the process.

The hot chamber die casting process is popular for its speed, accuracy and consistency. Additionally, it offers a longer die life and improved corrosion resistance.

Cold Chamber Die Casting

The cold chamber die casting process is similar to the hot chamber process, except that the metal is not melted in the casting machine.

The metal is melted in an external high-temperature furnace and transferred to the cold chamber die casting machine via a ladle. In the cold chamber machine, a hydraulic piston forces the metal into the metal die for casting.

This process is suitable for metals with higher melting points such as copper, magnesium, aluminium and their alloys. Magnesium alloys start melting at about 360°C (680°F) and go up to 650°C (1200°F). Therefore, some magnesium alloys can be cast using hot chamber die casting, while others can be cast using cold chamber die casting.

Metals with higher melting points offer greater strength, durability and hardness compared to low melting point metals. Therefore, cold chamber die casting is a better choice for demanding applications.

Advantages of Die Casting

The die casting process is a modern casting method with numerous unique advantages. Although it has been around for many centuries, it has garnered popularity in recent decades. Let’s explore the advantages of die casting to comprehend why it is a favored choice in the casting industry today:

Complex shapes are a breeze

The die casting industry can create highly complex shapes through this process. It is one of the few processes that can consistently produce high-quality parts at a rapid rate while maintaining narrow tolerances. The high pressures involved are capable of pushing molten metal into the thinnest channels with extreme reliability.

Master at mass production

The quick cycle times, high potential for automation, high material efficiency, and usage of low melting point metals make it highly effective for high-volume manufacturing. The industry uses the process in most serial production applications.

Made for the 21st century

The die casting process can seamlessly incorporate all the latest technology. It is highly compatible with automation and other supporting technologies such as 3D printing and simulation, CAM and CAD software.

First-rate low-cost operation

The cost per piece decreases significantly as the volume increases. Although the initial investment in mould creation and automation integration may be higher than other processes such as sand casting, it more than compensates for it by having one of the lowest operating expenses among all the various types of casting processes.

Buttery smooth finish

Die casting is popular for delivering one of the best surface finishes among casting processes. In many cases, finishing operations may not even be needed, and the product can be put to use after trimming off the excess material from the gating system components.

Additional finishing operations such as grinding, machining and powder coating are only necessary when the application requires a high-quality polish or specific textures.

Limitations of Die Casting

It is equally important to be aware of the limitations and shortcomings of a manufacturing process. Die casting limitations are as follows:

High initial investment

The die casting process involves a significantly higher initial investment compared to other processes. This aspect of die casting can deter interested manufacturers who only have a small number of parts to produce. The economic advantage of die casting lies in mass production. It is not suitable for manufacturing prototypes or small batches of products.

Turbulence can be an issue

The high-pressure injection of molten metal is likely to generate turbulence, which can result in defects like porosity. To address this, most foundries now use flow simulation during mould design. By optimising the mould design and casting process parameters, turbulence can be minimised in the majority of cases.

For example, the metal is initially pushed into the mould with a slow initial velocity to minimise turbulence and the formation of gas bubbles.

Size and weight limitations

Die casting is most suitable for small to medium-sized applications. There are practical limitations on the weight of die-cast parts, as larger castings will naturally require larger dies and related equipment. Process parameters, such as the clamping force and heat dissipation capacity, cannot exceed a certain limit.

As the size of the casting increases, the cost of the process also increases at a greater rate, rendering the process unfeasible beyond the inflection point. In such cases, alternative methods like centrifugal casting may be more appropriate, as they are better suited for larger or cylindrical parts, where uniformity and precision are critical.

To Sum It Up

The die casting process is a modern marvel that can produce the most delicate and complex shapes effortlessly. It surpasses other casting processes, such as sand casting and investment casting, in terms of speed, accuracy, consistency and surface finish. Aluminium die casting, in particular, has been widely utilised in manufacturing to create lighter vehicles while maintaining their original strength.

However, die casting’s disadvantages, such as high initial cost and limitations on size and weight, restrict its use to a small group of applications. Nevertheless, advancements in simulation and automation are enhancing die casting’s capabilities, ultimately expanding its scope within modern manufacturing.

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