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A standard engagement runs 8–12 weeks: 2 weeks for the on-site audit, 2 weeks for analysis and roadmap development, and 4–8 weeks of guided implementation with weekly KPI review. Larger multi-department projects may extend to 16 weeks.
Transforming businesses one step at a time
Our Process Optimization service focuses on improving foundry efficiency by analyzing workflows, identifying bottlenecks, and implementing measurable improvements.
We help reduce scrap, increase yield, and optimize operational costs using data-driven strategies.
Key Capabilities
End-to-end process audit
Yield and productivity improvement
Scrap and rework reduction
Energy optimization
Cost reduction strategies
Operational workflow redesign
Our Approach to Process Optimization
Foundries across iron, steel, and aluminum casting sectors routinely lose 8–20% of production value through hidden inefficiencies — inconsistent pouring temperatures, uncontrolled sand properties, poorly sequenced moulding lines, and reactive (rather than planned) maintenance cycles. Steel Support 24 addresses these losses with a structured, four-phase optimization framework.
We begin with a comprehensive process audit covering the full production chain from raw material receipt to final casting dispatch. Using time-and-motion studies, rejection log analysis, and energy consumption mapping, we identify the top five bottlenecks costing your foundry the most per month.
Our team then applies proven industrial engineering tools — Value Stream Mapping (VSM), SMED (Single Minute Exchange of Die) for pattern changeovers, and OEE (Overall Equipment Effectiveness) calculations — to build a prioritized improvement roadmap with clear ROI projections.
Implementation support includes on-site parameter standardization, operator training, and SOP documentation aligned with ISO 9001 process control requirements. We track yield, scrap rate, and energy KPIs weekly during the improvement phase.
Clients typically achieve 3–8% yield improvement, 25–40% reduction in internal rejection rates, and measurable energy savings within the first three months. Applicable to grey iron, ductile iron, steel, and aluminum casting operations of all scales.
Frequently Asked Questions
We request 6–12 months of rejection logs, monthly yield figures, energy bills, melt and pouring records, and current SOPs. If records are incomplete, our audit process helps reconstruct baseline data from operator interviews and live observation.
Yes. High-performing foundries often have significant hidden savings in energy consumption, changeover time, and rework hours. Above 85% yield, we shift focus to energy optimization, line balancing, and predictive maintenance to drive further cost reduction.