Consolidated Casting News/Events

January 2012

Consolidated Casting has added a Zeiss Contura G2 7.10.6 air bearing, high accuracy, multi- axis Coordinate Measuring Machine (CMM), complete with a VAST XT active scanning probe head. Carl Zeiss coordinate measuring machines are considered the world’s leader for coordinate measuring machines and a complete solution for multidimensional metrology.

To further advance manufacturing process control, Consolidated Casting has added a Thermo ARL 3460 Optical Emission Spectrometer, with Windows based operating system, process controls and ability to analyze Nitrogen.

July 26, 2011

Consolidated Casting Corporation has acquired an additional 12,000 square foot building located at 405 Lec Lane in Hutchins Texas, adjacent to its Warehouse & Distribution Center and Main Casting and Machining facility to support the growth plans for its core businesses of investment casting and CNC machining.

The expansion and planned improvements will result in a state-of-the-art, air-conditioned machining center that will increase machining capacity and improve the quality of CCC's products, as well as the working environment for its employees.

June 30, 2011

Consolidated Casting Corporation has recently added three outstanding new team members to support our growth and continued improvement initiatives, which we are very proud to introduce to you.

Production Manager

Wayne Brown joined CCC approximately 9 months ago. Since January, Wayne has filled in as our interim Quality Manager and last month he accepted a new position as Production Manager.

Wayne possesses a Bachelor of Science degree in Industrial Engineering with over 20 years of Operations Management experience working for various manufacturing companies including investment castings. Wayne has held prior positions in Manufacturing and Industrial Engineering, Cost Estimating, Quality Management and Production Management. He demonstrates exemplary performance in leading Lean Manufacturing Initiatives such as 5S and Visual Management, TPM and SMED's, Kaizen Events, Pull System, Kanban, Value Stream Mapping and Project Management. Wayne has a proven background in analyzing personnel and capital resources to find the best way to meet production quotas and insuring production standards are met; and, inventory levels are maintained.

Quality Manager

In May, Allen Miles joined the Consolidated Casting Corporation team as Quality Assurance Manager/ CNC Manufacturing Engineer. He will be responsible for quality management, CNC process development/improvements, implementation of lean manufacturing and automation. Allen has an extensive background in Quality Management, CNC Machining, automation, programming, fixturing and cutting tool design, and Six Sigma and has worked in the Automotive, Oil and Gas and Hand Tool Industries.

Prior to joining Consolidated Casting Corporation, Allen was with Geophysical Research Company in Tulsa, OK where he held the position of Quality Assurance Manager/ Senior Programming Technical Engineer.

Allen processes a Bachelor of Science Degree in Manufacturing Engineering from Grambling State University; he also holds certifications in ISO internal Auditing, 5S, IE Dojo, Six Sigma Yellow Belt, and Visual Management Systems.

Technical Director

In July, Steve Sliger will join our team as Technical Director. Steve has a Bachelors of Science degree in Metallurgy and brings with him 20 plus years' extensive knowledge and experience in the investment casting and Foundry industry. Steve has worked for other reputable investment casting companies both in the United States and China where he has held positions as General Manager, Sales and Engineer.  He was also very instrumental in setting up a successful investment casting operation in California and managing the wax pattern, ceramic molding, and casting departments.

Please join us in welcoming our newest team members at Consolidated Casting Corporation. We are confident that the combined talents and experience of these individuals will greatly enhance our overall capabilities and provide additional value- added services to our customers. 

January 2011

Consolidated Casting Featured in InCast Magazine

Consolidated Casting was featured in the January 2011 issue of InCast Magazine in a write-up of how Consolidated saved a client over $300k per year in part redesign. The write-up can be read here.

September 2010

Consolidated Casting Receives 5th Consecutive "Blue Thumb Award"

This year will be the 5th consecutive year that Consolidated Casting Corporation receives the "Blue Thumb Award", in recognition of its commitment to excellence, leadership and stewardship in protecting the environment.

This year CCC has also met the criteria to qualify for nomination for the Pollution Prevention (P2) Award. Mike Seay, registered environmental Manager (inspector) with the City of Dallas, has nominated Consolidated Casting for this very prestigious award.  

The 2009 Blue Thumb Award winners are displayed on a plaque at the Dallas City Hall.

For additional info visit the Dallas City Hall site.

June 2010

Consolidated Casting Passes Quality Audit With "Flying Colors".

Consolidated Casting Corporation is very proud to announce that we have recently passed our ISO-9001:2008 quality surveillance audit, with “Flying Colors”.

Consolidated Casting Featured In Design2Part Magazine Article

CCC was featured in Design2Part Magazine article

January 2010

Consolidated Casting Upgrades Machining Capacities With New Equipment

Consolidated Casting Corporation (CCC) has recently purchased and installed a new Mazak “Matrix” Nexus 350 MYZ x 80” QTN lathe with milling and “Y” axis capabilities to complement its fully equipped machining capacities, which now includes 35 CNC machines in addition to a wide range of conventional machine tools, enabling Consolidated Casting to provide turnkey products to its customers. Consolidated Casting Corporation is a leading, highly diversified manufacturer of precision investment cast components and assemblies for commercial and industrial applications, and for the industrial gas turbine (IGT) industry.

Consolidated Casting Installs New Burnout/Preheat Furnace

Consolidated Casting Corporation (CCC), a leading and highly diversified manufacturer of precision investment cast components and assemblies for commercial and industrial applications, as well as the industrial gas turbine (IGT) industry, has recently purchased and installed a new burnout/preheat furnace that will significantly improve its process control and the quality of its castings. The 40’ furnace also increases capacity by more than 50% and provides valuable cost savings through improved fuel efficiencies and productivity. The new furnace uses high velocity technology that provides uniform heat transfer to the mold and uniformity within the furnace chamber of +- 20 degrees F. Controls are PLC based with touch screen operator interface, which provides monitoring functions of the entire operation along with the fuel usage and oxygen levels within the furnace. The furnace is equipped with four (4) temperature controlled zones, which provides a wide variation of temperature profiles that the mold can be exposed to, depending on product mix. Maximum operating temperature is 2300 degrees F.

Shambaugh Named Director of Operations At Consolidated Casting Corporation

Scott Shambaugh has been named Director of Operations at Consolidated Casting Corporation (CCC), a leading and highly diversified manufacturer of precision investment cast components and assemblies for commercial and industrial applications, as well as the industrial gas turbine (IGT) industry. Scott is a metallurgical and manufacturing engineer with a Masters degree in business, and 23 years experience in the investment casting industry. Scott’s previous senior operations managerial experience at the largest, most advanced aerospace foundries in the world, his extensive technical manufacturing experience and his visionary leadership skills will greatly enhance CCC’s ability to develop and execute breakthrough strategies.

Consolidated Casting Corporation Receives ISO 9001:2008 Recertification

Consolidated Casting Corporation (CCC), the first investment casting company to have received QS-9000 certification, has announced that its casting, machining and welding facilities in Hutchins, Texas has received ISO 9001:2008 recertification, also noting that there were no major or minor non-conformances. CCC is a leading, highly diversified manufacturer of precision investment cast components and assemblies for commercial and industrial applications, and for the industrial gas turbine (IGT) industry.

Consolidated Casting Makes Major Expansion Investment

Consolidated Casting Corporation has recently invested over $2,000,000.00 to upgrade and expand our facilities, equipment and operating systems, resulting in greatly improved quality and delivery performance, reduced costs and lead times, and increased value added service to our customers. The changes include, but are not limited, to the following:

• New "Exact JobBOSS® " integrated manufacturing software enhances our scheduling, inventory control and capacity planning capabilities. Mobile computers are now positioned throughout the plant to provide more accurate and timely information on the status of your orders. Our new operating system and lean manufacturing processes are enabling us to greatly improve on-time deliveries and we are well on our way toward meeting our goal of 100% OTD.  
  
• General upgrading of our facilities has been completed, including a 6,000 sq. ft. building expansion.
  
• Our 15,000 square foot storage building has been completely renovated and converted into a painting, assembly, warehouse and distribution center to support the many value added services that CCC now provides.
  
• All key production equipment and machinery have been upgraded or replaced, including realignment of the knockout, cutoff, blasting and finishing departments, and automated material handling systems have been installed for continuous flow, lean manufacturing.  
  
• Aggressive scrap and rework reduction initiatives have been implemented to reduce costs, improve 1st time quality and on-time delivery.  
  
• New laser guided automatic cutoff and tumble blasting equipment were added to increase productivity and safety.
  
• New dust collection systems were installed to improve working conditions and air quality in the plant.
• High tech Solidification modeling software was added to optimize gating efficiencies and 1st time quality, reduce development time on new parts and reduce costs.