Value Selling Approach Design Services

Case StudyAn alliance to ensure
an ideal casting process
General Motors (GM) and ASK Chemicals formed
an Alliance of strategic partners to manage andoversee a major series production process transfer» BackgroundIn 2009, General Motors (GM) enteredinto a joint venture with the Uzbekistani government. The goal was toproduce the 1.2L & 1.5L B-DOCH(Family AB Double Over Head Camshafts) cylinder head in Tashkent, atthe newly built greenfield facility. Inorder to ensure their success, GMsought the assistance of strategic
business partners on matters pertaining to employee training, processoptimization and conversion.

General Motors came to ASK Chemicals, a leading solution-based foundry consumableprovider, to serve as project managers to ensure the seamless transition of their aluminum
cylinder head series production line in Uzbekistan. A strategic alliance was created with
two other corporations that contained specific expertise within the casting production
process: Anderson Global (tooling provider) and Wolverine Bronze Co. (prototyping andtesting facility). GM also played a key role by supplying an engineering team to support
and oversee every step of the process.
Anderson Global is a leading global tooling provider and specializes in optimizing toolingdesigns. Wolverine Bronze Co. is a prototyping and testing facility. Here, they containstate-of-the-art equipment required to test and verify series production manufacturing
processes.

» Objectives
ASK Chemicals, and the Allianceteam, were tasked with the objectiveof seamlessly transferring theproduction on GM's aluminum headcastings to the country of Uzbekistan.
Several milestone achievements wereidentified in achieving the success of
this project: complete casting andprocess optimization, regionallyadapted solutions, employee training,and ongoing training and support.
Within these latter goals were more
highly specified targets to be addressed by the Alliance team:

The Alliance team worked together on the following objective list. Below is a detailed
outline of the customer requirements and the primary responsible party within theAlliance.
ASK Chemicals:•• Develop optimized casting and core designsutilizing simulation software.
•• Reduce core and casting scrap considerably below 10%, but maximize production
up-time and productivity.
•• Ensure the process is seamlessly transferred to GM and GM Uzbekistan.
Anderson Global:•• Produce an optimized tooling build that would feature a core box, semi-permanent molds
and auxiliary fixtures and gages.
•• Semi-permanent molds must accommodate a Fata turntable production process.
Wolverine Bronze Co. & ASK Chemicals•• Establish a core strength range suitable within Uzbekistan's geographical climate.
•• Ensure an efficient shakeout timing sequence.
•• Guarantee efficient gating and riser removal plus cycle time and repeatability.

What is the ASK Chemicals Value Selling Approach?

“It's a truly collaborative effort, first-and-foremost. The ASK
value-adding model leverages our extensive knowledge-base andfoundry experience in order to enhance process efficiencies.
Sometimes it's also referred to as "solution selling". Here, thesupplier works hand-in-hand with the customer to address their
specific needs. The eventual outcome, as seen with GM Uzbekistan, is the efficient and successful completion of stated goals/requirements.

”» Solutions
Leveraging their greatest assets theAlliance team developed a plan tomeet GM's objective parameters.
Ultimately, this stage was incredibly
revealing, as it was a testament to theAlliance team's capabilities andexpertise. Furthermore, it demonstrated the efficiency and speed atwhich solutions could be derived
given thorough planning and testing.
ASK Chemicals, for example, usedsimulation software to realisticallydemonstrate casting integrity. Thus,
any problematic situations could beidentified and remedied before actualproduction.

ASK Chemicals:
Simulation engineers at ASK used Arena-flow® software - widely considered the mostaccurate core shooting simulation system available - to design the entire core box fromthe ground-up: blow magazine, individual cores and box. Once designed to the ideal
specifications, pouring simulations could commence:•• Magma® software was used to project both the metal fill-time and solidification time•• Potential porosity issues/rates were realized, as well as overall projected mechanicalproperties
Anderson Global:
The physical tooling build occurred at Anderson Global and resulted in an optimized 100L
production core box made from high-grade steel - produced on a Loramendi coremachine.
•• Auxiliary fixtures and gages were constructed of steel, renwood plastic and aluminum.
Wolverine Bronze Co.
The pre-production prototype testing site was located at Wolverine Bronze Co. Here,their goal was to ensure an optimized casting production process while considering theavailable resources and climate of Uzbekistan.
•• Core strength tests were conducted to ensure a statistical probability of success given
regionally available resources and climate conditions.
•• X-ray imaging, dimensional sectioning testing, CMM measurement analysis and 		metallurgical examination provided further insight.
ASK Chemicals: (Post Casting Process)» ResultsAfter completing all phases of theproject ASK Chemicals, alongside
their Alliance partners, provided
launch support and training to GMUzbekistan. This took place in boththe United States, as well as Tashkent and included the newly acquired
foundry personnel.

•• Developed a custom recipe to ensure complete sand removal from the casting•• Robotic automation system established to efficiently remove gating and risers•• Specification of production equipment run-off to ensure efficient cycle times•• Complete process documentation for easy knowledge-transfer

Today, the GM Uzbekistan plant is producing an average of 2,000 cylinder head castings
per day. These go directly into the neighboring engine assembly plant and supply theUzbekistani and Asian automotive market. The seamless production transfer was thanks
to the dedication and process efficiency of the Alliance team, as well as GM and theirsupport team.
The final process documentation delivered to GM Uzbekistan encompassed the results ofthe project and would serve as reference to their manufacturing site in the future:•• Flow diagrams•• Process control plans•• Tooling design manuals•• Core/casting process manuals» About ASK CHEMICALS
Our wide product range contains binders for all core manufacturing
processes, coatings, additives, feeders, filters, release agents,
metallurgical products including inoculants, Mg treatment wires,inoculation wires and pre-alloys for iron casting. Core production
and prototype development as well as a wide range of simulation
services round off what the company has to offer.

This information is based on our current state of knowledge and does not represent assurance of the properties of the products described. We are only
liable for product-related advice and information within the scope of duties of disclosure included in collateral contractualagreements unless expressly
agreed otherwise. (02 / 15)

ASK Chemicals is one of the largest
suppliers of complete solutions andtailor-made consultation services forthe foundry industry. The core of ourcompany’s activity involves manufacturing all foundry consumables
required for the production chain as
well as providing optimum technicalservices in order to perfectly adapt ourproducts to the processes on thecustomer’s premises.