Case Study #1
An aluminum forger supplying commercial and automotive markets engaged MCG for a state-of-the-art assessment to assist in developing business plans to improve its competitive posture and re-position the company for growth in both markets. This study contrasted the company’s current capabilities in forging and tooling design, tooling manufacture, forging engineering, forging processes and equipment, thermal processes and ancillary supporting processes to the industry state-of-the-art for the manufacture of high volume parts. Major cost reduction, throughput improvement, reprocessing reduction, and product enhancements were shown to be possible for two key processes. Each of these processes is now being more rigorously evaluated using process analysis, process understanding and process optimization techniques to develop tactical plans including capital investments. Cost reductions to 31%, throughput increases to 22%, and reprocessing reductions to 28% are projected.

Case Study #2
A forging company serving the global turbine engine market asked MCG to help establish its strategic and tactical business plans. The investigation focused on historical, state-of-the-art, and future trends for the key forging technologies for producing critical titanium, superalloy and steel turbine engine parts. MCG conducted detailed market, customer, supplier and competitor analyses to establish the trends. Data were obtained from sixty interviews conducted worldwide with turbine engine and airframe OEM’s, forgers, raw material producers, academia, and several DOD agencies. In this way, it was possible to categorize the future production of turbine engine parts by hammer forging, press forging and isothermal forging. This study led to a re-direction of the company’s strategic plans and a decision to undertake a rigorous performance management program.

Case Study #3
A manufacture of trailer axles experienced premature failures during production testing of a new design that was being readied for market. Prototype production axles performed as designed and the failures were unexpected. Since commitments were made to deliver the axles to key customers it was essential that the failure be resolved as quickly as possible. MCG was engaged to assess the manufacturing process and help resolve the premature failure problem. MCG determined that the forming process was not at fault but that failure was caused by a combination of material surface quality and poor heating practice. Recommended process changes enabled the company to meet the rollout timetable for the new axle and satisfy customer delivery requirements.

Case Study #4
Die temperatures in excess of 1000°F often are desirable for precision forging of steel, titanium and superalloys. But most commercial water-base graphite die lubricants do not adhere well to dies heated above 600°F and excessive spray of the lubricant is required to coat the die. In one forging plant more than 80% of the graphite lubricant spray was dispersed into the atmosphere as soon as it contacted the die surface. Such waste is not only costly – it pollutes the workspace and equipment. MCG metalworking lubrication specialists markedly improved the company’s lubrication practices. Modifications to the commercial graphite lubricant made it possible to easily apply the lubricant to dies heated to 1100°F without overspray in a much shorter spray cycle. The result: lower lubricant costs, cleaner work environment, and improved forge press productivity.