Cost per kg unknown
Quotes use last year's rates while metal and power costs move every month.
Fixed with: Live per-kg costing from actual heats
Heats and charge mix, chemistry, patterns, sand, production, casting QC, yield and per-kg costing in one system, built for iron, steel and non-ferrous foundries.
Each stage records its weights, times and results, so yield and cost build up automatically from the shop floor.
Each one costs money on every heat. Each one has a fix.
Quotes use last year's rates while metal and power costs move every month.
Runners, risers and rejects are never weighed against metal melted.
Spectro results sit on paper and corrections are guessed.
Customer patterns are hard to locate and their condition is unknown.
The same defect returns because causes are not recorded.
A sample grey iron part. Change the casting weight, yield, metal and power cost and rejection rate to see what each good casting really costs. Figures are illustrative.
Includes ₹22 per kg for moulding, sand, fettling and overheads. Runners, risers and rejects go back to the furnace and are credited at 80% of metal cost.
Each heat records its charge mix, power and temperature, and spectro results are checked against the grade. Sample heat for grade FG 260.
Each card opens a detailed module page.
From melt to good castings, the losses are weighed at each step. Yield on this sample is 602 ÷ 955 = 63.0% of metal poured.
Each pattern has an owner, rack location, mould count and repair history. Patterns due for repair are flagged before they cause defects. Sample rack.
Green sand tests are recorded each shift. The needle shows today's value and the orange band is the limit for this line. Sample results.
Rejections are logged with defect codes. The Pareto shows the few causes behind most rejections, so the foundry fixes those first. Sample month, 90 rejected castings.
Bars: rejected castings by defect. Line: cumulative share, reaching 79% after the top three causes.
Heat data, chemistry and weights flow in without manual entry.
A typical single-foundry rollout with a pilot line before full go-live.
Typical improvement targets we plan against, not guarantees.
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ERP for neighbouring industries and the services that complete your system.
Straight answers to what foundries ask us most.
An ERP for casting makers. It manages patterns, moulding, heats and melting, charge mix and chemistry, sand, production, casting QC, yield and per-kg costing alongside purchasing, sales, inventory and accounts.
Yield is the weight of good castings divided by the weight of metal poured (or melted). Runners, risers, spills and rejects make up the difference, and most of it returns to the furnace as foundry returns.
Cost per kg of good casting adds metal cost, melting power, moulding and sand, fettling, overheads and the cost of rejected castings, then divides by good weight. The ERP uses actual heat data, so costs move with metal and power prices.
Yes. Each grade has chemistry limits. The ERP records the charge mix and spectro results for each heat and flags values outside the limits.
Yes. Each pattern has an owner, location, mould count, condition and repair history, so you can find it and know when it needs work.
Yes. Moisture, green compression strength, permeability, compactability and other tests are recorded against limits, with additions logged per batch.
Yes. Rejections are recorded with defect codes by part, mould line and shift, giving a Pareto of the biggest causes.
Typically about 9 to 11 weeks for one foundry, including parts, patterns, grades, heats, sand, QC, costing, training and a pilot.
Tell us what you want to build, your products, plants and current tools. We reply within 4 business hours with honest advice.