Reducing scrap rates for plants and foundries around the world
At Monitizer, we are helping leaders and pioneers of our industry around the world to reduce scrap. Since this quote, Morikawa, has gone on to digitize its whole casting process with us.
Here are some of our global scrap reduction success stories.
- Scrap reductions at every install for Grede, US
- Scrap reduction of 54% for AI-optimized compliant castings at Condals, Spain
- 86.9% scrap reduction on pattern at Morikawa, Japan
— Mr Junichi Morikawa, President, Morikawa, Japan‘We are particularly astonished by the excellent results of the pattern that showed 86.9% uplift, since we had been unable to reduce the scrap rate for this pattern before, no matter what measures we had taken.’
Every single Grede plant that launched Monitizer achieved fast reductions
Grede are America’s premier iron casting provider, serving automotive, commercial truck and industrial markets since 1920. Their efforts to improve productivity and performance have seen a large-scale adoption of IIoT with our suite of products. The benefits in terms of scrap reduction have been seen immediately.
‘Of the plants that have launched Monitizer, within 4 months, one-hundred percent have seen a scrap reduction…We’ll take that for a quick win.’ - Susan Bear Sabet, Chief Technology Officer, Grede US
Over 54% scrap reduction for AI-optimized compliant casting at Condals in Spain
Condals uses Monitizer to centralize real-time data across its foundries. This gives supervisors, engineers, and operators complete visibility of production processes. This translates to improved decision-making, strengthened process stability and enhanced operator compliance with the Manresa plant achieving significant scrap reductions.
‘Scrap rates on average were 51.8% lower for Line 1 and 56.4% lower for Line 2 when compliant with the prescriptions over a period of six months.’ - David de la Cruz, Chief Digital Officer, Condals
Scrap reductions giving a huge competitive advantage in Japan
A longstanding customer for DISA – one of the companies in our group- Morikawa uses high-speed, vertical DISAMATIC® moulding machines. The foundry now expects our suite of IIoT tools to provide a significant competitive advantage and transform it into a digital leader.
‘The results of the MONITIZER | PRESCRIBE first test showed an uplift of 66.6% and 86.9% respectively for the two different patterns. We are very satisfied with these results. We are particularly astonished by the excellent results of the pattern that showed 86.9% uplift, since we had been unable to reduce the scrap rate for this pattern before, no matter what measures we had taken.’ - Mr Junichi Morikawa, President, Morikawa, Japan
