Foundry operations software

Pour more good iron with the crew you already have.

Ferridyne brings scrap, heat, process and quality data together so foundries can see what rejected castings cost and investigate what happened around them.

We are starting with scrap and the pour, then building outward into the rest of the foundry.

Estimate your scrap cost See what we're building
Data Ferridyne can work withERP recordsSpectrometer resultsSand lab dataSpreadsheetsScrap logsTravelers
01 / Start with scrap

Put a dollar number on it.

Most shops track scrap as a rate. The estimate below turns your rate into dollars using your own numbers: the metal, the melt time and labor, and the castings you could have shipped instead.

9,000tons
8.0%
$80/ ton
$540/ ton
Estimated cost of that scrap per year
$485k

Metal you re-melt, furnace hours you burn twice, and labor poured into parts that never ship.

Castings scrapped783 t
Metal re-melted$63k
Furnace + labor sunk$423k

An estimate from your inputs, not a measurement. The real number comes from your production records. That's where we start.

02 / Platform

Start with the scrap. Follow it back to the heat.

Ferridyne is being built around a simple workflow: quantify the scrap, connect it to the production record, and give the people running the foundry a better way to investigate what happened.

Scrap cost · by partSample data
PartScrap %ScrappedCost / mo
Housing 44-B11.2%218$41.6k
Brake drum 77.8%604$38.2k
Manifold M26.1%140$22.9k
Pump body P94.4%92$14.1k
Valve 3103.9%310$9.8k
Internal
$96k
After machining
$61k
At customer
$27k
Shrinkage on Housing 44-BPour temp was 10–18° below target on 71% of rejected heats. Line 2, second shift.
71%
Gas porosity on Brake drum 7Gas index above 60 ppm on cupola heats with long holds.
54%
Inclusions on Manifold M2Coincides with sand LOI drift after Tuesday reclaim change.
38%
Pour temp
2,710 °F
Gas index
74 ppm
Fade time
3.4 min
Yield
96.6 %
H-4471 · Line 2 · Housing 44-BPour temp 2,662°F, 18° under target. Similar conditions were recorded on 71% of this part's rejected heats.
Review
H-4472 · Ductile · Brake drum 7Treat-to-pour at 9.1 min. Prior rejects on this part clustered above 8 min.
Review
Last 7 daysSurfacedReviewedNoted
Line 1443
Line 2976
DISA222

The crew makes the call.

03 / Modules

Start with scrap. Build outward from there.

We are building Ferridyne around the operating work of a foundry. Scrap analysis and heat records come first. Other capabilities follow from the same production data.

Now

Scrap & melt

The first three pieces, built around the heat.

Module

Scrap cost

Cost by part, line, heat, defect and shift.

Module

Melt & heat records

Charge, chemistry, temperatures, treatment and related production data connected to the heat.

Module

Defect investigation

Compare rejected castings with the conditions recorded when they were produced.

Next

What we're building next

Following from the same production data.

We are deliberately building this with foundries rather than trying to reproduce every feature of an ERP.

04 / How it fits

Start with the information the foundry already has.

Ferridyne is intended to work alongside the systems and records already used in the plant.

FerridyneBrings it together
↓ reads
ERP dataStays
Spectrometer results · lab recordsStays
Scrap spreadsheets · travelers · production logsStays

The first job is bringing enough of that information together to understand where scrap is happening, what it costs and what was happening when it occurred.

From there, we decide with the foundry what is worth building next.

05 / How we start

Bring us a real scrap problem.

Pick a part, defect, line or recurring problem that is costing the foundry money. We start there.

  1. 01

    Gather the records

    Scrap history, production records and whatever process data is available.

  2. 02

    Put a dollar number on it

    Understand the size of the problem by part, line, heat or defect.

  3. 03

    Connect the production history

    Look at what was happening around the rejected castings: chemistry, temperature, treatment timing, sand, shift, line and other available variables.

  4. 04

    Find what is worth investigating

    Surface patterns, unusual conditions and recurring combinations for the foundry team to examine.

  5. 05

    Build from there

    If the work is useful, extend Ferridyne into the next problem.

Bring us a casting problem worth fixing.

Give us a recurring scrap problem and the records you have around it. We'll start there.