IN THIS ISSUE

Advanced Magmasoft® Process Simulation
Licensed by CWM for Die Casting



Chicago White Metal Casting has upgraded its in-house process simulation technology to the powerful Magmasoft® high-pressure die casting simulation software system. It enables more rapid optimization of die casting process parameters prior to die construction for the highest-quality casting results.

Interfacing with customer CAD files, extensive databases, and its 3D modeler, the new software allows rapid analysis of a product’s design, tooling, and process variables for optimum first-piece success. CWM engineers believe that the Magmasoft system is, today, the best predictor of the performance of a die casting die design. It provides a best estimate of the mechanical properties that can be expected in the final cast part.

The bottom line for OEMs is reduced lead time, improved quality assurance, and lower manufacturing costs. Arrange a visit to CWM to see CWM’s Magmasoft workstation in action.

To arrange a CWM Plant visit, and see a Magmasoft metal flow simulation, contact your CWM Regional Sales-Engrg Representative or the CWM Sales Dept.

The authors state in the study that many companies pursue cheap labor without recognizing that labor can make up just a small fraction of total manufacturing costs for many products. Looking back at 10 years of design-for-manufacturing cost-reduction work, Dewhurst estimates that labor costs for typical product assemblies are just four percent, versus 72 percent for parts and material costs, and 24 percent for overhead.

In addition to overestimating labor costs, a number of costs associated with offshore sourcing are not fully added to the calculation: often overlooked, according to the report, are shipping costs, especially shipping losses, travel, communication, and vendor selection. Also often missing are the costs of dealing with engineering and marketing changes, higher prices for certain materials offshore, legal work, new workforce training, theft and piracy. And finally, the cost of poor quality that can require constant vigilance to maintain.

Dewhurst and Meeker make the case that all of these added and hidden costs come to, conservatively, at least 24 percent of final manufacturing costs, and for many products, lower labor rates cannot cover these added expenses.

The study argues for leveraging product reengineering to create lower cost product designs. Part count reduction resulting in significant cost savings should be at the heart of such product redesign programs. Low offshore labor rates are often mistakenly viewed by many companies as the easier alternative to large unit cost savings.

What about redesigning the product for lower costs and then offshoring it? They caution that the newly optimized design will still be subject to the extra 24 percent offshoring costs.

CWM would point out that die casting, along with plastic injection molding, is a primary manufacturing process that can deliver substantial unit cost savings through product redesign. For many products, where the properties and look and feel of metal are important, advanced die casting technology can dramatically reduce part counts and improve product performance.

The North American Die Casting Assn. has published its own study, "The Hidden Costs of Offshore Sourcing." For a copy, contact your CWM Regional Sales-Engrg Representative, or request a copy from the CWM Sales Dept.

Scored

The long-term goal of the program is to enable strategies leading to significant reductions in pollution, waste, environmental and human health impacts, with a decrease in regulatory burdens. CWM's latest report to the Performance Track program included:

Reductions in Chemical and Process Water Usage
Reductions of 21% in the amount of die casting die lubricant used in the aluminum die casting department and of 50% in the amount of SF6 gas used in the magnesium die casting department, despite increased production in both departments; Elimination of approximately 4,000 lbs. per year of chemicals used to treat process water through the installation of a new environmentally friendly process water system; Reduction by 22% in the amount of process water used company wide.