badger foundry company 103 years of excellence
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Badger Foundry Company 103 Years of Excellence. 1910 - 2012. Our Product is Iron… Our Strength… People Quality Policy. - PowerPoint PPT PresentationTRANSCRIPT
Badger Foundry CompanyBadger Foundry Company 103 Years of Excellence103 Years of Excellence
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Quality PolicyQuality Policy
The Quality Policy of Badger Foundry The Quality Policy of Badger Foundry Company is to provide high quality castings Company is to provide high quality castings and customer services that meet our and customer services that meet our customers’ expectations. We are customers’ expectations. We are committed to continually improving our committed to continually improving our quality management system processes and quality management system processes and increasing Customer Satisfaction through increasing Customer Satisfaction through the use of measurable quality objectives.the use of measurable quality objectives.
Angus R Callender, PresidentAngus 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… PeopleOur Product is Iron… Our Strength… People Significant MilestonesSignificant 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
1970sBadger 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.
1995
Badger installs electric furnace dedicated to the production of ductile iron castings giving the Company new abilities
2005
Employees – Average length of service is Employees – Average length of service is 15 years. 15 years.
Committed to employee safety Committed to employee safety Financial StrengthFinancial Strength ISO 9001-2008 CertifiedISO 9001-2008 Certified On time deliveryOn time delivery Personal and proactive service on each Personal and proactive service on each
account. account. Design Support Design Support
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Key Strategic Items / beliefs Key Strategic Items / beliefs
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People CapabilitiesCapabilities
Iron: Iron: Gray and Ductile IronGray and Ductile Iron
Casting Weights:Casting Weights: Gray - 100 lbs. – 4000 lbs. Gray - 100 lbs. – 4000 lbs. Ductile – 100 lbs. -2500 lbs.Ductile – 100 lbs. -2500 lbs.
Melt Capacity: Melt Capacity: Gray - 130 tons/daily Gray - 130 tons/daily
Ductile - 35 tons/dailyDuctile - 35 tons/daily
Green Sand Flask Sizes:Green Sand Flask Sizes:Typical: 24X24, 40X40, 36X62Typical: 24X24, 40X40, 36X62inchesinches (Designed to fit your product)(Designed to fit your product)
No Bake Flask Size:No Bake Flask Size:Custom, up to 80X80 Custom, up to 80X80 inchesinches
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Facility Facility
Cupola and Electric MeltCupola and Electric Melt 40 Ton Holding Furnace40 Ton Holding Furnace 3 Green Sand Molding Lines3 Green Sand Molding Lines 2 No Bake Lines – large cast2 No Bake Lines – large cast 3 No Bake Core Make Lines3 No Bake Core Make Lines Automated Process Control TechniquesAutomated Process Control Techniques Extensive Handling EquipmentExtensive Handling Equipment Sand LabSand Lab MetrologyMetrology Pattern ShopPattern Shop 135,000 sq. ft. facility135,000 sq. ft. facility
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Plant LayoutPlant Layout
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Product ManagementProduct Management
Badger maintains a high quality Badger maintains a high quality supplier base to accommodate Tier 1 supplier base to accommodate Tier 1 functions. functions.
PaintPaint Heat Treat Heat Treat MachineMachine
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People
Continuous ImprovementContinuous Improvement
HousekeepingHousekeeping LeanLean 5’s5’s 2009 – 7 Events2009 – 7 Events 2010 – 5 Events2010 – 5 Events 2011 – 6 Events2011 – 6 Events 2012 – 5 Events2012 – 5 Events 2013 – 2 Event2013 – 2 Event 151 Employees151 Employees
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Environmental ProgramsEnvironmental Programs
Air Pollution Control Equipment Air Pollution Control Equipment On-site sand disposalOn-site sand disposal Several recycling programsSeveral recycling programs Reclaim ProcessesReclaim Processes Storm Water and Air Emission Storm Water and Air Emission
ControlsControls Title V Title V
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Environmental ProgramsEnvironmental Programs
Raw material storage.Raw material storage. Byproducts are segregated Byproducts are segregated
and stored for recycling.and stored for recycling.
Environmental ProgramsEnvironmental Programs Beneficial reuse of excess foundry sands. Beneficial reuse of excess foundry sands.
Applications used: Cement production, fill for Ag Applications used: Cement production, fill for Ag and general projects.and general projects.
Plant lighting project saving 1,426,332 lbs of CO2 Plant lighting project saving 1,426,332 lbs of CO2 emitted each year.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 Salvage iron and steel from reuse sand. 120 tons
of remelt last (2) years.of remelt last (2) years. Coke breeze recycled as a fuel source=94 tonCoke breeze recycled as a fuel source=94 ton
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Process FlowProcess Flow
FinishFinish
Pattern/ToolingPattern/Tooling
Produce CoreProduce Core
Produce MoldProduce Mold
Raw MaterialsRaw Materials
Green SandGreen Sand No BakeNo Bake
MeltMelt
PourPour
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Raw MaterialRaw Material
High quality materials are purchasedHigh quality materials are purchased Supplier Approval ProcessSupplier Approval Process Detailed Specifications Detailed Specifications Dedicated working Relationship Dedicated working Relationship Advanced planning activityAdvanced planning activity
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Pattern EngineeringPattern Engineering
Electronic transfer of blueprint information for Electronic transfer of blueprint information for work stations using Pro-E, Catia, Anvil, work stations using Pro-E, Catia, Anvil, Unigraphics, or I-DEAS.Unigraphics, or I-DEAS.
Badger also utilizes online communication tools Badger also utilizes online communication tools such as “Same Time” and “Web X” .such as “Same Time” and “Web X” .
Solidification Modeling is conducted to ensure Solidification Modeling is conducted to ensure casting soundness.casting soundness.
Validate casting to model and modeling also Validate casting to model and modeling also
available.available.
Showing liquid above 15%.
View angle x/y/z: 32/40/135
Casting Solidification SimulationCasting Solidification Simulation
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Melt ProcessMelt Process
Extensive process control and chemistry Extensive process control and chemistry analysis.analysis.
Ductile – Specifically prepared batches / Ductile – Specifically prepared batches / heats to meet each customers needs.heats to meet each customers needs.
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People LabLab
Fully Equipped LabFully Equipped Lab• Chemistry:Chemistry:
Leco – Carbon DeterminaterLeco – Carbon Determinater Spectrometer – 17 ElementsSpectrometer – 17 Elements
• Complete Greensand and Chemically Complete Greensand and Chemically Bonded Sand TestingBonded Sand Testing
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Molding ProcessMolding Process
No BakeNo Bake Green SandGreen Sand Automated sand controlAutomated sand control
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Core ProcessCore Process
Complex core design and assembly. Complex core design and assembly. Proprietary blends to accommodate Proprietary blends to accommodate
customer needs.customer needs. Shell coresShell cores
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Finishing ProcessFinishing Process
Hanger & Tumble BlastHanger & Tumble Blast Skilled InspectorsSkilled Inspectors
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Process InstructionsProcess Instructions
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People Our ProductOur Product
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People ContactsContacts
Jeff SchaetzJeff Schaetz Loren WadewitzLoren WadewitzV.P. Manufacturing ManagerV.P. Manufacturing Manager Quality ManagerQuality Manager(507)452-5760(507)452-5760 (507)452-5760(507)452-5760jschaetz@[email protected] [email protected]
Chuck WillChuck Will Frank KunceFrank KunceV.P. SalesV.P. Sales Foundry Engineering MgrFoundry Engineering Mgr(262)650-8480(262)650-8480 (507)452-5760(507)[email protected]@wi.rr.com fkunce@[email protected]
Kim HardyKim Hardy Mike BaderMike BaderSalesSales Account Manager - SalesAccount Manager - Sales(507)452-5760(507)452-5760 Cell (920)373-5725Cell (920)373-5725Sales@[email protected] Office (507)452-5760Office (507)452-5760
[email protected]@gmail.com
Our Product is Iron… Our Strength… PeopleOur Product is Iron… Our Strength… People LocationLocation
1058 East Mark Street1058 East Mark Street
Winona, MN 55987Winona, MN 55987
