Proven where the metal is poured.

MaintenanceIQ ships a licensable Foundry & Metals module, and casting manufacturers run it on their floors today. We do not publish their names, and we do not publish numbers about their results that they have not agreed to share.

Customer names withheld.

A foundry that makes thousands of different parts in many alloys has a records problem as much as a maintenance problem. Every furnace, press, autoclave and instrument needs planned maintenance and calibration. Every heat, pour and casting needs a record that an automotive or energy customer can audit.

The Foundry & Metals module puts both on one record. It sits on Core CMMS, so work orders, preventive maintenance, calibration, spare parts and downtime are already there. On top of that it adds:

• A foundry asset tab with furnace type, melt capacity, refractory lining, rated campaign life and live wear percentage
• Heat and melt logs, with a refractory campaign that projects the next reline date
• Pattern master, pour records and outcome records by defect code and stage found
• Casting yield and a defect Pareto computed from those records, never typed in
• Spectro chemistry checked against alloy grade bands
• Green sand control for sand shops, and shell room and shell weight control for investment shops
• Condition monitoring, granted automatically with the module
• VDA 6.3 and IATF 16949 evidence packs built from the same records

Our foundry records changed because a design partner on a casting floor showed us something we had wrong. An early version folded casting outcomes onto the heat record. Feedback from an investment caster showed that melting and casting are separate stages, owned by different people at different times.

So we rebuilt the model. A heat, a pour and an outcome are now separate records, captured by three roles on three screens, and every number that crosses stages, such as yield, is computed from them. That is the kind of change we expect to keep making with the plants that use MaintenanceIQ.