Metalcasting for Purchasing Professionals

Overview

This course provides a foundational introduction to metalcasting, designed specifically for buyers and supplier development professionals who are new to the industry. Participants will explore the major casting processes, learn how to select and audit metalcasting suppliers, understand the critical elements of the Production Part Approval Process (PPAP), and develop strategies for managing quality problems when they arise. The course concludes with a practical look at total cost of ownership, long-term agreements, building a portfolio of approved casting suppliers, and strategies for building redundancy and contingency into a metalcasting supply chain.

Learning outcomes

Class participants will learn to:

Describe various metalcasting processes and explain how metalcasting differs from other industries.
Describe the current state of the metalcasting industry.
Identify important considerations in selecting a metalcasting supplier, including foundry audits.
Describe key elements of the metalcasting production part approval process (PPAP).
Identify the seven primary metalcasting defect categories and the 10-step process to eliminate defects.
Describe surcharges and the concept of Total Cost of Ownership.
Identify the critical elements and pros and cons of long-term agreements.
Identify the key elements of building a portfolio of approved metalcasting suppliers.
Describe strategies for building redundancy and contingency into a metalcasting supply chain.

Course Length

2.0 days

CEU Units

1.20 CEU

Course outline

MODULE 1: METALCASTING INDUSTRY OVERVIEW

What is Metalcasting?
The Metalcasting Process

MODULE 2: STATE OF THE METALCASTING INDUSTRY

U.S. Supply Base and Structure
Demand Trends and Market Outlook
Reshoring, Tariffs, and Sourcing Trends

MODULE 3: TYPES OF METALCASTING PROCESSES

Sand Molding
Permanent Molding
Die Casting
Investment Casting
Rapid Prototyping

MODULE 4: CHOOSING A METALCASTING SUPPLIER

My Tier 1 Supplier is a Machine Shop. Why Does it Matter Where They Source Castings?
Foundry Audits

MODULE 5: PRODUCTION PART APPROVAL PROCESS (PPAP)

What is PPAP?
The 18 PPAP Elements
PPAP Submission Levels
Critical Elements and Best Practices

MODULE 6: HELP, I HAVE POROSITY! UNDERSTANDING CASTING DEFECTS

Defect Categories
Common Defects
The AFS 10-Step Procedure

MODULE 7: SURCHARGES

What are Surcharges?
Metal and Alloy Surcharges
Energy and Fuel Costs
Tooling, Minimum Orders, and Other Costs
How Surcharges Are Calculated and Best Practices

MODULE 8: TOTAL COST OF OWNERSHIP (TCO)

TCO in Metalcasting
The Five Pillars of Casting TCO
Hidden Costs
Building a TCO Model

MODULE 9: LONG-TERM AGREEMENTS

Why Long-Term Agreements Matter
Essential Contract Elements
Pricing & Escalation Clauses
Risk Management Pitfalls
Negotiation Best Practices