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Newby Foundries | Grey & ductile iron casting | UK
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Address:
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Smith Road,
Wednesbury,
West Midlands,
UK
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Postcode:
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WS10 0PB
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Country:
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UK
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Phone number:
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0121 556 4451
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Fax number:
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0121 505 3626
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Website:
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http://www.newbyfoundries.co.uk
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Contact name:
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Nick Newby
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Email address:
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nick.newby@newbyfoundries.co.uk
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WMCCM Rated:
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yes
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Profile:
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Newby Foundries Ltd. is a market leader in the supply of Grey & Ductile Iron castings.
Iron Casting Processes.
Investment in three foundries provides significant capacity, up to 120 tonnes per week in the shell foundry alone, in the following iron casting processes.
Vacuum backed shell moulded casting, between 30-100 kg per piece, in the shell foundry.
Shell moulded casting, up to 30 kilo per piece, in the shell foundry.
Greensand snapfast moulded casting, up to 10 kg, in the greensand foundry.
Airset (no bake) iron casting from 500 kg up to 5 tonnes in the large traditional foundry.
Newby Foundries are a major supplier to the automotive industry, meeting their quality requirements with ISO TS16949-2002 approval and processes, and their competitive requirements with global supply chain management.
Product areas include;
Turbochargers
Vacuum Pumps
Valves
Hydraulic parts
General Engineering castings
Iron Casting Materials.
Newby Foundries have wide experience in all of the main iron casting materials including:
Casting in spheroidal graphite iron, sg iron, ductile or nodular graphite iron.
These iron castings contain graphite in the form of nodules or spheroids.
Casting in ni-hard iron, cast iron to which nickel has been added to make it resist abrasion.
Casting in ni resist iron, cast iron consisting of graphite in a matrix of austenite.
Casting in grey iron, or flake iron.
Services
Newby Foundries offer the following services.
Design and simulation.
Rapid prototyping. Significant new investment to speed your products to market.
Global sourcing. World value, local support, with sampling, verification, PPAP, etc managed for the customer.
Machining, finishing and painting.
Non-destructive test certification.
KanBan and stocking agreements.
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Ethos:
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Quality
Through carefully developed operating procedures our quality standards are continuously being raised, and is recognised in the following accreditations.
ISO / TS16949-2002
QS9000
ISO9001-2000
The Mark-Out department is equipped with a computer assisted 3 axis co-ordinate measuring machine (C.M.M.)
This set-up allows us to dimensionally assess tooling and sample castings to PPAP requirements quickly and accurately. Printed results of findings can be generated for customer approvals.
Our Quality Department is supported by well equipped laboratory facilities, enabling us to carry out spectrographic analysis, mechanical and non-destructive testing including dye-penetrant, ultrasonics, magnetic particle and endoscopy.
Design and Simulation.
The use of state of the art high-speed computers, along with the most advanced software enables our methods engineer to accurately simulate both the flow of molten metal within the mould cavity, and the subsequent solidification characteristics. This is an invaluable tool in minimising pattern development time and ensuring a “Right first time” methoding solution.
Potential problems such as, shrinkage porosity, cold laps, and misrun can be identified and resolved without the need for costly and time consuming pattern, mould and casting production.
Our in house casting design team provides informed advice on casting design, materials and process selection, to identify at the onset of a project the optimum casting solution, and minimise the lead time to market.
Rapid Prototyping.
The foundry production development department also uses rapid prototyping facilities to help assess casting shape for manufacturing. RP models can also be used to create low budget tooling producing prototype castings for testing and appraisal.
People
Newby Foundries investment in training and staff development is recognised in the Investors In People, IIP, award.
The desire to become a lead player in the production of high quality castings is dependent upon maintaining the skills of the entire workforce. To meet the new challenges we are committed to a training programme, which will be used to improve the skills of all shop floor employees, management, clerical and administrative staff.
RMZ 17/08/2004
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Basic line of business:
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Grey and Ductile iron casting. Shell moulded iron casting, vacuum backed shell moulded iron casting, greensand, snapfast moulded, iron casting & airset (no bake) iron casting.
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Products and services:
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Turbochargers
Vacuum Pumps
Valves
Hydraulic parts
General Engineering
Casting in spheroidal graphite, sg, iron, ductile or nodular graphite iron. These iron castings contain graphite in the form of nodules or spheroids.
Casting in ni-hard iron, cast iron to which nickel has been added to make it resist abrasion.
Casting in ni resist iron, cast iron consisting of graphite in a matrix of austenite.
Casting in grey iron, aka flake iron on account of all or part of the carbon content being in the form of graphite distributed through the metal as flakes.
Newby Foundries offer the following services.
+ Design and simulation.
+ Rapid prototyping. Significant new investment to speed your products to market.
+ Global sourcing. World value, local support, with sampling, verification, PPAP, etc managed for the customer.
+ Machining, finishing and painting.
+ Non-destructive test certification.
+ KanBan and stocking agreements.
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Runners:
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0%
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Repeaters:
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95%
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Strangers:
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5%
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Number of Employees:
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100
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Annual Turnover (£m):
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5
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Annual Rate of Growth (%):
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6
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Reference customers:
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BOC Edwards,
Holset,
3K
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Continuous improvements:
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The continuous improvements is driven by the TS16949:2002 processes including;
TS16949 Improvement Groups.
FMEA.
Six Sigma implementation for key projects.
etc.
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Competence transfer:
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New Product Introduction Service
Global Sourcing Lifecycle Management
More complex water-cooled turbocharger parts
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Key processes:
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Key Process:
Casting,Consultancy,Prototyping
New Product Introduction Management Service
(Mastery: Under Development, Time In Operation: 1.00 year)
Key Process:
CAD / CAM,Mechanical Design
CAD (Solid Works)
(Mastery: Mature, Time In Operation: 2.00 years)
Key Process:
CAE/Simulation,Casting,Mechanical Design
Solidification Modelling System
(Mastery: Mature, Time In Operation: 10.00 years)
Key Process:
Casting
Shell Moulding Casting upto 30kgs (Volume - low thousands per week)
(Mastery: Mature, Time In Operation: 40.00 years)
Key Process:
Casting
Vacuum Backed Shell Casting 30 to 100Kg (Volume - upto 100 per week)
(Mastery: Mature, Time In Operation: 2.00 years)
Key Process:
Casting
Airset castings or no-bake casting.
This large and dedicated foundry has a casting capacity of up to 4 tonnes in Grey Iron and 3 tonnes in S.G. and NI Resist Irons, and is capable of handling a wide range of castings in any grade of iron.
(Mastery: Mature, Time In Operation: 40.00 years)
Key Process:
Casting
Greensand casting shop, using both Shell Moulding and Snap Flask moulding processes, produces medium volume output of grey, white and white-heart malleable castings. Ideal for small volumes, 50 up, and a fast turn-around of 3 to 4 weeks for many jobs.
(Mastery: Mature, Time In Operation: 20.00 years)
Key Process:
Fettling
Consistant and accurate finishing of castings using;
2 x Robotic Fetelling machines
(Mastery: Mature, Time In Operation: 2.00 years)
Key Process:
Casting,Electric Furnaces
Electric Melting using
6 x Electric Induction Furnaces
supported by heavy overhead crianage and conveyor systems for flexible pouring into casts.
(Mastery: Mature, Time In Operation: 20.00 years)
Key Process:
Global Supply Management,Procurement
Global Supply Chain Management
(Mastery: Mature, Time In Operation: 9.00 years)
Key Process:
CMM,Measuring,Quality Control
The Quality Department is supported by well equipped laboratory facilities, enabling spectrographic analysis, mechanical and non-destructive testing including dye-penetrant, ultrasonics, magnetic particle and endoscopy. The Mark-Out department is equipped with a computer assisted 3 axis co-ordinate measuring machine (C.M.M.) This set-up allows us to dimensionally assess tooling and sample castings to PPAP requirements quickly and accurately.
(Mastery: Mature, Time In Operation: 10.00 years)
Key Process:
Laser Sintering,Rapid Prototyping
Rapid prototyping service using the latest
sintering technology
(Mastery: Under Development, Time In Operation: 0.50 years)
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Key skills:
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Role: HR and Development
Human Resources
Human Resources Director
(Skill Level: Expert, Years of Practice: 11.00 years)
Role: Senior Director
Metallurgist
Chairman
(Skill Level: Expert, Years of Practice: 40.00 years)
Role: Senior Management
Casting,Mechanical Engineering,Metallurgist
Technical Director
A degree in metalurgy, with extensive experience in the simulation and design of castings.
(Skill Level: Expert, Years of Practice: 30.00 years)
Role: Senior Management
Casting,Manufacturing Engineering,Metallurgist
Managing Director
From a metalurgy background with a wealth of experience of the casting industry and senior management.
(Skill Level: Expert, Years of Practice: 30.00 years)
Role: Chartered Accountant
Accounting
Finance Director
(Skill Level: Expert, Years of Practice: 20.00 years)
Role: Product Development Manager
CAD/CAM,Casting,Design
CAD / New Product Introduction
(Skill Level: Certified, Years of Practice: 6.00 years)
Role: Quality Manager
Casting,CMM,Quality Assurance
Quality manager who has introduced the latest accreditations to TS16949:2002 etc
(Skill Level: Expert, Years of Practice: 25.00 years)
Role: Foundry Manager
Casting,Mechanical Engineering,Metallurgist
A time served engineer with wide experience in casting and metalurgy.
(Skill Level: Experienced, Years of Practice: 30.00 years)
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Locations:
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England, GB, UK, Wednesbury, West Midlands
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Markets:
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Automotive, Commercial Vehicles, Precision Engineering, Pumps & Valves
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Standards:
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Investors in People, ISO 9001:2000 - QMS Requirements, ISO/TS 16949:2002, QS 9000:1994
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Print Close
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Status: approved
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Last Updated: 07/09/2006 12:31:27
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