Practical guides for foundry owners, plant heads and QC teams on choosing ERP, costing, quality and digitalisation, from a team with 12+ years in metal casting.
Buyer's checklistTo choose foundry ERP software, list your plant's pain areas first, test every vendor on your own foundry use cases in the demo, and confirm the system was built for foundries: heat-wise traceability, pattern and method records, and separate moulding, melting and pouring entries. Then check scalability, total cost, local service and references.
Cost per kgCasting cost per kg is the total manufacturing cost of a batch divided by the saleable casting weight, not the metal melted. Include net metal and alloys, melting energy, moulding consumables, labour, finishing, inspection, rejection and overheads. For example, ₹2,00,000 of batch cost over 800 kg of good castings is ₹250 per kg.
ERP ROI: 7 metricsTo measure ERP ROI in a foundry, record your numbers before go-live, then compare them at 3, 6 and 12 months on seven metrics: staff time, charge-mix cost, inventory turns, production efficiency, loss-making items, breakdown days and machine-integration savings. ROI = (annual benefit − annual ERP cost) ÷ annual ERP cost × 100.
Casting yieldHow to calculate casting yield, why it sets your cost per kg, and how to track it heat by heat. Formula, worked example and practical ways to improve it.
Rejection ParetoA step-by-step method to analyse casting rejection by defect, pattern, heat and shift, find the few causes that matter, and cut rejection month after month.
EN 10204 certificatesWhat EN 10204 type 2.1, 2.2, 3.1 and 3.2 inspection documents mean, what a 3.1 material test certificate for castings must contain, and common mistakes.
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ICAST tracks yield, rejection and test certificates heat by heat, on your shop floor.
