Project Overview
A pump OEM faced a critical production gap. Most of the company’s castings fell in the 60- to 150-pound range. A high-volume foundry handled those.
But that wasn’t the end of the story. The OEM also required much larger castings for specialized applications – including pumps used on aircraft carriers. These larger, low-volume castings fell outside the scope of its existing supplier.
To meet demand, the OEM needed to identify a new foundry capable of handling oversized, low-quantity castings.
However, several concerns stood in the way:
- How could the OEM be confident the new foundry could meet performance and quality expectations?
- What would happen to decades-old tooling that needed to be transferred and preserved?
- Would adding another vendor – especially for limited production – create more inefficiency than value?
To solve this, the manufacturer engaged Joel Yates, a seasoned consultant with decades of foundry experience and deep expertise in metallurgy.
Finding The Right Foundry
Yates had prior experience working with State Line Foundries and knew its specialty: low-volume castings at virtually any size.
“If I need a casting that’s 40 pounds or 2,500 pounds, they can do it,” Yates says. “That’s unique.”
He also knew State Line would provide quality and on-time delivery. Against this background, he evaluated State Line against the project’s specific challenges.
Key Challenges
Low-Volume Production
Many parts required only two to three units per year, making traditional mass-production foundries inefficient and cost-prohibitive.
Tooling Transfers
Legacy tooling – some more than 50 years old and even made of wood – needed to be carefully transferred, disassembled and adapted without damage.
Vendor Consolidation
Production for non-standard sizes was currently spread across multiple foundries. This increased complexity, cost and logistical inefficiencies.
Communication Gaps (Previous Suppliers)
Earlier vendors struggled with poor communication and a lack of proactive problem-solving, leading to defective castings and rework.
State Line’s Approach
1. Flexible Production
- Ability to produce castings from 40 to 2,500 pounds
- Efficient handling of one-off and low-volume orders
- Adaptability across a wide range of sizes and specifications
2. Tooling Integration Expertise
- Careful handling and restoration of legacy tooling
- Experience working with complex, outdated and wooden patterns
- Seamless integration into existing production
3. Strong Communication
- Consistent updates throughout production
- Proactive engagement to clarify requirements
- Collaborative, solutions-oriented approach
4. Vendor Consolidation Support
- State Line’s capabilities enabled sourcing of multiple part numbers
- Reduced reliance on multiple foundries
- Simplified coordination and supply chain management
5. Logistics Optimization
- Consolidated shipments reduced freight costs
- Integration into regular delivery schedules eliminated fragmented (and costly) shipping
- Improved overall efficiency versus “one pallet here, another there,” as Yates described
Results
- Successful transfer and production of 50+ part numbers
- Improved casting quality compared to previous suppliers
- Reduced number of vendors and streamlined supply chain
- Lower shipping costs through consolidated logistics
Conclusion
What began as a search for a niche capability evolved into a strategic advantage – combining flexibility, technical expertise and strong communication.
State Line didn’t just fill a production gap. It enabled the manufacturer to simplify operations, improve quality and gain greater control over its supply chain.
Do you have a project with tight timelines and high complexity?
Contact State Line to make sure your next critical project is an unqualified success!