Watry finds accurately simulating the entire casting process a huge advantage when communicating to customers why a design change is necessary. Customers find the software impartial, keeping the emotions out and making decisions based on facts. Watry’s customers recognize the need to run the simulation and are more apt to go along with design changes when presented with the simulation results.
“Having MAGMASOFT® cuts across all disciplines, whether it’s manufacturing, quality or sales and marketing. Even time spent in the tool room. Now, we have less and less rework of the mold needed before it makes a good part,” Dannenberg says.
Sales and engineering, as well as the quality department, have all seen the benefits in the decrease in lead times. All departments are positively affected by the reduction in time from inception of the project to completion of the part. Mike Kamin, Engineering Manager, says, “Lead time has definitely shortened, we spend more time up front, but we don’t sample three, four or five times before we get a quality part. We are more likely to make a good, quality part the first day it’s in the machine. It used to be we were a long way away from making a good part on the first day, pulling and making gating changes was very common. It just isn’t common anymore. The software gives us the opportunity to dig through a lot; everything from processing and moldmaking back to part design. It helps us really do some fine tuning to get to that ‘good part quality’ a lot more quickly and with minimal iterations.”
The foundry has gone back to parts they were producing for years and started running them through MAGMASOFT® to make them better and more up-to-date. Quality Manager Gary Haas adds, “There are many parts we make that have been around for a long time. What was good quality 5-10 years ago is not acceptable anymore, so we use MAGMASOFT® in a lot of retro jobs, as we go back and look at a part to see what improvements we can make.” Dannenberg adds, “We see MAGMASOFT® as an indispensable tool that Watry customers have come to expect. As a matter of fact, before having the license, it was the high level customers who own MAGMASOFT® themselves who mandated it back our way.
Watry has seen the benefits how the tool helps reduce the cost of their work, in general. Having the software changes how quality functions overall and, most importantly, it reduces scrap. Sales sees process simulation as a necessity, not an option. It separates Watry Industries from their competition. It reduces costs overall, while strengthening ties with customers, as the foundry is perceived as being more forward-thinking and tech savvy.