columbia steel super-sizes to success: this steel foundry has molded itself into a successful caster of large components through diversification, expansion and a commitment to optimizing production resources.
by：QY Precision 2019-10-02
Columbia Steel Foundry, Inc. Portland, Oregon, found the secret to the success of the casting industry: Making worn parts. The 385- Cast wear parts for staff steel alloy facilities such as cone crusher bowl liner and coat, traction chain, coal mill tires for power plant, freezer grille for cement plant and rotor cover for automatic shredder, all of this encountered enough wear at work to grind off the casting surface and required frequent replacement. Columbia Steel is a foundry that has been operating since 1901, experiencing and thriving in wear and tear The component market is mainly due to the continuous management, diversity, expansion and commitment to recycling and environmental protection. Here\'s how Columbia steel works and what can be learned from this operation. The simplest conformance statement for consistency management is this: from 1920, only four people are in charge of maintenance. In addition, 45 existing employees have worked in the foundry for more than 25 years. The staff stayed at Columbia steel for a long time and was probably subject to 56- Chairman of the board, H. M. \"Bud\" Bird. After leaving the Coast Guard in 1946, Bird assumed the father\'s ownership responsibility at the foundry, and since then, Bird\'s father, Hobart, has remained at the foundry, where he began working at Columbia Steel in 1916, and strive to gain ownership. \"The Foundry has passed the slow period quite well because Sir Birds have a long time \"The company\'s long-term vision has been reinvested,\" explains advertising manager Alan George . \". \"Having a private owner can really help the business. \"Employees know exactly who they work for,\" he added . \". This loyalty can bring dedication to the company\'s employees. On 1957, after the foundry burned down, employees offered to work free of charge before the reconstruction was completed. Workers\' commitment to bird and Columbia Steel, coupled with Bird\'s decision to rebuild the plant rather than fold, is one of the keys to the lasting success of the foundry. The more roots the tree has, the greater its stability. If diversity can be considered to be the root of a steady-growing tree, Columbia Steel stands on a solid footing. Markets Served-- The company\'s roots come from dredging, mining and logging, and sawmill products, but after the transition to help wartime efforts during World War II, as demand for large wartime castings has disappeared, the company began to enter other markets. As a result, a diversified program that is expanding every decade has been launched. In their 50 s, during the construction of Interstate Highways in the United States. S. The Foundry entered the market for aggregate and metal mining. In the early 70 years, waste treatment equipment was introduced, and in the later 70 years, coal mine products and80s cement-Make products. Since the target of the foundry is cost Efficiency, it pursues other applications with current customers, such as the complete rotor assembly of scrap shredder. Over the past decade, Columbia Steel has started producing power plants and submersible pump components. Another key to diversity is partnership. Byrd said building partnerships with other small businesses in the market and complementing our strengths is something that has to be done. This \"enter the market, otherwise you will not benefit. \"For Columbia Steel, this is the market for pumps and big moppers,\" he said . \". Although the types of markets served have expanded dramatically, the choice is not arbitrary. \"We choose a market where we can add value to our customers. We sell products, not castings. \"Marty Cox, chief financial officer, said. Services provided- Columbia Steel also offers a diverse range of services including sample shop, engineering center, manufacturing department, welding department, heat treatment oven and mechanical processing zone. These services stem from the strategic plan of the foundry, including the decision to manufacture finished products in a centrally managed vertically integrated facility. Demand for expanded facilities and increased customer base has driven the foundry to grow, and five years after the fire in 1957, it moved from its original plant to its existing location in northern Portland. Expansion: Growth of Foundry new foundry location from 280-ft- There are long foundry and office building. This has gradually expanded to its current size: 18 buildings, covering 86 acres and an area of 450,000 square feet. Continue on a virtual tour of Columbia steel foundry. Patterns-- Of the total square feet of the foundry, 115,000 square feet are pattern storage. This includes more than 21,000 models, including 2000 new products ( Changes to new and old designs) Produced every year. Most of the patterns built by 18 molding workers are wood. The pattern shop has a wood lathe, a patterned Mill, tables and controlled environment rooms with Saw, planing, carpentry, Sanders and paint and plastic. Coreroom-- Due to the safety factors and fire resistance of the materials, Columbia Steel uses Olive sand to produce the core. The foundry handles 140,000 tons of sand/year while keeping the sand formula at its lowest level. After producing the cores, they are cleaned and burned to remove moisture and transferred to the molded building. The Nobake refunding machine handles the recovered core sand for 7 tons/hour. Molding-- According to the size and quantity of the castings produced, the foundry has 8 different molding production lines. * Molding group 1 and 7: These two groups make green sand type for the largest products of Columbia Steel using overhead slingshot. The first group makes molds for the doll and bowl liner of 7-7 Using 105 ft cone crusher A flask of diameter. Group 7 in 90- 130 in diameter. * Molding group 2 and 4: medium and short term and medium term moldsCasting size (Up to 10,000) Use 52-produce here Tons/hour of sand. * Molding Group 3: this half Production 36x12/12 of automatic molding production line Handle and drag the mold; * Molded Group 6: small castings produced here by Colombian steel using match plates, loose, coping and dragging patterns. * Forming Group 8: This half Production 36x66x14/14-in. Models for coping and dragging (Fig. 1); * Molding group 9: produce large chains in this molding group using the nobake mold. In order to make a large chain, each other link is prefabricated and placed in a special mold, and the link is poured around the mold to form a chain (Fig. 1). The biggest chain of production is 6- A chain of 865 pounds each. Melting pouring- Colombia buys scrap steel locally and buys worn-out castings from customers. Melting and pouring occurs mainly in three electric furnaces: two 10-ton and one 4- Tons, two tons at a time, capable of melting up to 250 tons of steel/day. 5 induction furnaces ( 1,000 to 2,200 each- Lb retention capacity) Used with smaller runs. Four 20- Tons of hot metal cranes transport metals from furnaces to large molds (Fig. 2). Shakeout, grinding, cleaning and heat treatment-- After cooling, the casting vibrates in one of the four vibrations of the main foundry. Grapples picked up the casting, most of which were too large to lift manually, and the air cannon knocked the gate and the riser off. The castings enter one of the five air-free shot blasting machines; Maximum, 12 feet diameter, can handle 20-ton loads. Since most of the products cast are for high strength applications, the castings are heat treated in 15 10 to 50 months Heat treated oven ton. Machining, welding, etc. -- The foundry created the Columbia engineering plant, a 70,000-sq- In 1996, the ft machine store named after the original foundry. Recognize the big niche In large-scale machining and manufacturing work, Columbia Steel transferred its existing machine tools, including CNC machine tools, to new buildings and added more equipment. A vertical drilling mill of 18-18, the planing bed and the horizontal mill are connected togetherft- 6x22-vertical boring mill with diameter Ft CNC planing bed for 20x30x9ft 50- Tons of heat treatment furnaces, manufacturing and welding facilities. The capacity of the plant enables the foundry to sell at any timeto- Rotor assembly using Shredder (Fig. 3) Weighing 96,000, casting and processing of the spindle, rotor arm and wear cap is required. Upon completion, it has become a rotating assembly with bearings, bearing housing and drive coupling that can be placed in the shredder. Working to reuse the foundry constantly asks itself how the technology is changing and what it can do to make those changes happen, reducing costs and getting other benefits. Many improvements to the implementation of the Capital Planning Commission\'s decision also have environmental improvementsbased benefits. Water recycling- The foundry uses six closed The recycling system used for water treatment has reduced new water use by 98% in 10 years. The system allows the foundry to recycle 1. 5 million gallons of water per day. Water charges have risen by 2300% over the past 20 years, but due to low water consumption, the foundry pays the same monthly fees as they did 20 years ago. Sand Filling-- At present, the sand loss of Columbia Steel Company is 5%, with the target of 1- Fill 2% of sand through improvement. Reduce the loss of sand 3- 4% will lead to one- Annual return period. To achieve this, another set of sand filling equipment will be installed soon. Lighting and electricity- The company recently completed most of the lighting renovation of 18 buildings. According to the advice of a power consultant, it replaced more than 400 high-voltage sodium bulbs with low wattage metal halogen lamps and modified 400 fluorescent lamps with smaller bulbs and energy-saving ballasts. These changes save 750,000 KW hours/year and create brighter working conditions for employees. Air Cleanliness- The foundry has 21 bags that collect dust and discharge 500,000 cubic feet of air/mm. And run with capture efficiency of more than 99%. \"Over the past decade, we have been working on an ongoing positive plan to identify and minimize our remaining air pollution sources. In the field of air pollution control, we are considered to be a \"small natural source \"( Lowest possible category) Bruce Schacht, environmental engineer, explained: \"The Environmental Protection Agency. Columbia Steel\'s recycling and environmental efforts have a significant impact on both the environment and the cost of casting. \"This recycling adds up to 200 tons of scrap steel, 600 tons of sand, 1. \"There are 5 million gallons of water per day,\" Schacht added . \". Since Columbia Steel opened its doors for the first time, the company has focused on more than 100 years in the future, despite continuous development. Economic and market changes. The company\'s private holding, consistent management continues to look for new markets, expand the capacity of its facilities and recycle its production resources. Related article: Columbia Steel Foundry, Inc. Metal Casting in Portland, Oregon: manganese, high-strength margoing, chromium-molybdenum, heat-resistant stainless steel and carbon steel, and chromium-alloy iron. Mold ability: green sand and nobake. Core competencies: Nobake and oil sands. Melting capacity: Arc and induction. Size: 450,000 square feet. Service Market: Aggregate, cement plant, open-air coal mine, metal mining, coal- Power plants, scrap crushing, solid waste recycling and brick making. Employees: 385. Year of establishment: 1901 Management Team: N. M. \"Bud\" Bird, chairman of the board of directors; Mr. President Don Falk. Martha Cox, chief financial officer; Phil Rolf, marketing director; Bruce Johnson, vice president and chief engineer