Waupaca铸造 has been a forward user of technology since its inception in 1955 and has continually undergone significant technological transformations. 最值得注意的是1967年, we installed an automatic vertical molding line – which was the first of its kind in the United States – to improve efficiency. 在90年代早期, automation was implemented into our mill rooms and so began the gradual transition away from the manual grinding of castings. In 2019, we began a mill room expansion project at Plant 2/3, including the installation of two new robotic finishing cells (with more updates to come).

While technology has become the forefront of how we conduct our operations, a few of the largest impacts have been on our casting quality, efficiency in 能源 usage and the changing nature of labor we house.
 
铸件质量
根据 美国铸造学会, 90 percent of all durable goods depend on metal casting components, emphasizing the need for top-notch castings to be produced.

At Waupaca铸造 in the 1960s, iron castings were hand-poured with the use of a bull ladle. 今天, we utilize an automated process that allows for unmatched reliability and casting capability; Our molding line is 30 percent more productive 比我们的竞争对手.

Hand-drawn sketches and blueprints were once used to draw casting designs. 今天, casting designs are all computer-generated, and we use MAGMA 3-D Solidification Modeling to project casting fluid flow, 模拟凝固, iron flow and cooling long before castings are sampled or mass-produced. 另外, we use Laser-Scanned Dimensional Analysis to scan parts before they are poured to assure the castings are effective and consistent. If not, changes can be made before production. 今天, the industry widely uses this technology. Waupaca铸造 is proud to be among the first.

最近, Waupaca铸造 evolved with the introduction of additive manufacturing as a means to launch parts faster while bypassing design constraints (The first instance of additive manufacturing at Waupaca铸造 being 3-D printing cores and 3 D printed molds).
 
能源效率
Since 2004, Waupaca铸造 has executed many 能源 conservation programs with the help of technology.

In 2008, Waupaca铸造 implemented a closed-loop heat recovery system that utilized the heat generated to melt iron to be recycled back into the plant – accounting for 70 percent of the plant’s heating requirements in the winter. Not only was the project environmentally friendly resulting in the reduction of 4,600 metric tons of carbon dioxide per year, but it was also cost-efficient – saving approximately $900,每年000.

After, Waupaca铸造 set forward on a 10-year sustainability journey 全公司的, which included becoming a more 能源-efficient company by reducing 能源 usage by 25 percent.
From the program baseline year of 2009 to 2018, we had reached a cumulative 能源 intensity improvement of 21.3%.

In 2011, our Marinette, Wisconsin location installed a closed-loop cooling water system, which reduces water cooling demands, resulting in a near savings of 225,000 gallows of daily water usage and zero non-contact cooling water discharges. The system has also been implemented at our locations in Waupaca, Wisconsin; Tell City, Indiana; and Etowah, 田纳西州.

在一般情况下, we monitor machines’ capabilities through metering to reduce 能源 waste and improve 能源 efficiency. Robots standardize casting processes, which reduces the likelihood of human error on a casting, which in turn reduces the 能源 needed to re-manufacture an insufficient part and instead optimizes it.
 
劳动的性质
With greater sources of advanced technology present in our facilities, the nature of labor for our team members has changed.

用我们的机器人细胞, team members can take on higher-skilled positions, which results in higher wages. The work, overall, is safer, and the robots taking on the heavy lifting and repetitive tasks. This allows our team members to spend more time performing inspections and quality checks.
根据柯克·卡利奥的说法, 人力资源经理, technology has had huge implications on the dynamic of our workforce.

“Technology has helped us retain employees in an environment that proves to be challenging to remain in. 然而, 与技术, the job has become physically easier, the quality of the product is the same every time, and it allows a diverse workforce to continue working in these jobs that are becoming increasingly less taxing.”
 
Whether to improve casting quality, 能源 efficiency or work conditions, Waupaca铸造 uses technology to continuously improve operations, and we will continue to seek out new opportunities and advancements.