Badger Foundry Company 103 Years of Excellence.

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Presentation transcript:

Badger Foundry Company 103 Years of Excellence

Our Product is Iron… Our Strength… People Quality Policy The Quality Policy of Badger Foundry Company is to provide high quality castings and customer services that meet our customers’ expectations. We are committed to continually improving our quality management system processes and increasing Customer Satisfaction through the use of measurable quality objectives. The Quality Policy of Badger Foundry Company is to provide high quality castings and customer services that meet our customers’ expectations. We are committed to continually improving our quality management system processes and increasing Customer Satisfaction through the use of measurable quality objectives. Angus R Callender, President Angus R Callender, President

Badger installs a 1,000 lb/min. continuous mixer and reclamation equipment to enhance large casting production Our Product is Iron… Our Strength… People Significant Milestones Badger Foundry Co. is founded in Racine, WI 1910 Angus Callender (current president’s grandfather) becomes a controlling shareholder 1920 Richard Callender (current president’s father) takes over as president of Badger 1940 Badger’s operations are moved to an acquired space of 35,000 sq. ft. in Winona, MN 1949 Badger installs overhead sand transportation equipment improving efficiency of the production process 1952 Badger makes significant capital investment particularly in the core area and expands its facility size to 115,000 sq. ft. 1980s 2002 Angus Callender, current president, becomes president of Badger Badger builds a new 60,000 sq. ft. facility and moves to the new space Badger adds 20,000 sq. ft. of space and installs new machinery to increase production capacity 1970s Badger implements no-bake process that gives the Company the ability to produce large castings of up to 5,000 lbs. and added sq. footage to bring the total to 135,000 sq. ft Badger installs electric furnace dedicated to the production of ductile iron castings giving the Company new abilities 2005

Employees – Average length of service is 15 years. Employees – Average length of service is 15 years. Committed to employee safety Committed to employee safety Financial Strength Financial Strength ISO Certified ISO Certified On time delivery On time delivery Personal and proactive service on each account. Personal and proactive service on each account. Design Support Design Support Our Product is Iron… Our Strength… People Key Strategic Items / beliefs

Our Product is Iron… Our Strength… People Capabilities Iron: Gray and Ductile Iron Casting Weights: Gray lbs. – 4000 lbs. Gray lbs. – 4000 lbs. Ductile – 100 lbs lbs. Ductile – 100 lbs lbs. Melt Capacity: Gray tons/daily Gray tons/daily Ductile - 35 tons/daily Ductile - 35 tons/daily Green Sand Flask Sizes: Typical: 24X24, 40X40, 36X62 inches (Designed to fit your product) No Bake Flask Size: Custom, up to 80X80 inches

Our Product is Iron… Our Strength… People Facility Cupola and Electric Melt Cupola and Electric Melt 40 Ton Holding Furnace 40 Ton Holding Furnace 3 Green Sand Molding Lines 3 Green Sand Molding Lines 2 No Bake Lines – large cast 2 No Bake Lines – large cast 3 No Bake Core Make Lines 3 No Bake Core Make Lines Automated Process Control Techniques Automated Process Control Techniques Extensive Handling Equipment Extensive Handling Equipment Sand Lab Sand Lab Metrology Metrology Pattern Shop Pattern Shop 135,000 sq. ft. facility 135,000 sq. ft. facility

Our Product is Iron… Our Strength… People Plant Layout

Our Product is Iron… Our Strength… People Product Management Badger maintains a high quality supplier base to accommodate Tier 1 functions. Badger maintains a high quality supplier base to accommodate Tier 1 functions. Paint Paint Heat Treat Heat Treat Machine Machine

Our Product is Iron… Our Strength… People Continuous Improvement Housekeeping Housekeeping Lean Lean 5’s 5’s 2009 – 7 Events 2009 – 7 Events 2010 – 5 Events 2010 – 5 Events 2011 – 6 Events 2011 – 6 Events 2012 – 5 Events 2012 – 5 Events 2013 – 2 Event 2013 – 2 Event 151 Employees 151 Employees

Our Product is Iron… Our Strength… People Environmental Programs Air Pollution Control Equipment Air Pollution Control Equipment On-site sand disposal On-site sand disposal Several recycling programs Several recycling programs Reclaim Processes Reclaim Processes Storm Water and Air Emission Controls Storm Water and Air Emission Controls Title V Title V

Our Product is Iron… Our Strength… People Environmental Programs Raw material storage. Raw material storage. Byproducts are segregated Byproducts are segregated and stored for recycling. and stored for recycling.

Environmental Programs Beneficial reuse of excess foundry sands. Applications used: Cement production, fill for Ag and general projects. Beneficial reuse of excess foundry sands. Applications used: Cement production, fill for Ag and general projects. Plant lighting project saving 1,426,332 lbs of CO2 emitted each year. Plant lighting project saving 1,426,332 lbs of CO2 emitted each year. Water usage improvements saving 40% annually. Water usage improvements saving 40% annually. Reclamation of No Bake Sand. Reclamation of No Bake Sand. Blaster Sand Reclamation. Blaster Sand Reclamation. Salvage iron and steel from reuse sand. 120 tons of remelt last (2) years. Salvage iron and steel from reuse sand. 120 tons of remelt last (2) years. Coke breeze recycled as a fuel source=94 ton Coke breeze recycled as a fuel source=94 ton Our Product is Iron… Our Strength… People

Our Product is Iron… Our Strength… People Process Flow Finish Pattern/Tooling Produce Core Produce Mold Raw Materials Green Sand No Bake Melt Pour

Our Product is Iron… Our Strength… People Raw Material High quality materials are purchased High quality materials are purchased Supplier Approval Process Supplier Approval Process Detailed Specifications Detailed Specifications Dedicated working Relationship Dedicated working Relationship Advanced planning activity Advanced planning activity

Our Product is Iron… Our Strength… People Pattern Engineering Electronic transfer of blueprint information for work stations using Pro-E, Catia, Anvil, Unigraphics, or I-DEAS. Electronic transfer of blueprint information for work stations using Pro-E, Catia, Anvil, Unigraphics, or I-DEAS. Badger also utilizes online communication tools such as “Same Time” and “Web X”. Badger also utilizes online communication tools such as “Same Time” and “Web X”. Solidification Modeling is conducted to ensure casting soundness. Solidification Modeling is conducted to ensure casting soundness. Validate casting to model and modeling also available. Validate casting to model and modeling also available.

Showing liquid above 15%. View angle x/y/z: 32/40/135 Casting Solidification Simulation

Our Product is Iron… Our Strength… People Melt Process Extensive process control and chemistry analysis. Extensive process control and chemistry analysis. Ductile – Specifically prepared batches / heats to meet each customers needs. Ductile – Specifically prepared batches / heats to meet each customers needs.

Our Product is Iron… Our Strength… People Lab Fully Equipped Lab Fully Equipped Lab Chemistry:Chemistry: Leco – Carbon Determinater Leco – Carbon Determinater Spectrometer – 17 Elements Spectrometer – 17 Elements Complete Greensand and Chemically Bonded Sand TestingComplete Greensand and Chemically Bonded Sand Testing

Our Product is Iron… Our Strength… People Molding Process No Bake No Bake Green Sand Green Sand Automated sand control Automated sand control

Our Product is Iron… Our Strength… People Core Process Complex core design and assembly. Complex core design and assembly. Proprietary blends to accommodate customer needs. Proprietary blends to accommodate customer needs. Shell cores Shell cores

Our Product is Iron… Our Strength… People Finishing Process Hanger & Tumble Blast Hanger & Tumble Blast Skilled Inspectors Skilled Inspectors

Our Product is Iron… Our Strength… People Process Instructions

Our Product is Iron… Our Strength… People Our Product

Our Product is Iron… Our Strength… People Contacts Jeff SchaetzLoren Wadewitz V.P. Manufacturing ManagerQuality Manager (507) (507) Chuck WillFrank Kunce V.P. SalesFoundry Engineering Mgr (262) (507) Kim HardyMike Bader SalesAccount Manager - Sales (507) Cell (920)

Our Product is Iron… Our Strength… People Location 1058 East Mark Street Winona, MN 55987