Renault Improves Yield and Produces Over 520 More Parts per Hour

Casting
Ground Transportation
After using ESI QuikCAST, not only were we able to increase our bottom line by saving on metal and creating more castings than before, but we also implemented a completely new system for casting that we now use routinely across various product lines within the company
Laurent SOULAT Casting Specialist Renault Process Engineering

Challenge

Renault needed to define design rules for the filling and feeding systems for casting processes on different product lines in order to enhance competitiveness and achieve high quality production.

Story

Fonderie de Bretagne (FDB) joined the Renault Group in 2009 and is now a wholly owned subsidiary. The company produces rough and machined parts in spheroidal graphite cast iron and other materials. Renault has made a considerable investment in installing a new molding line at FDB. In the scope of commissioning the new line, Renault decided to standardize their production methodologies and to use simulation early in the development cycle. This meant devising a standard for creating molding layout and feeding design that could be replicated across a wide range of casting products. For the pilot project, they chose an existing 6-cavity mold layout of a cast iron knuckle; one already in production but experiencing some noticeable shrinkage porosity problems.

Benefits

Using ESI QuikCAST, part of ESI’s casting solution, Renault was able to enhance competitiveness, reduce development time and cost and improve product quality. Most importantly they increased their know-how of filling and feeding systems for casting and established new production design methodology.