One of the economic criteria used to justify the software acquisition was to increase the overall annual metal yield to a target of 58% on average. In 2007, just before MAGMASOFT® was installed, the average yield in the foundry was around 50.7%. During the first year of using MAGMA's software, the average yield was increased to 55.5%.
This encouraging beginning allowed SULZER to start manufacturing more complex and technically advanced castings, finally improving the company’s turnover and bottom line. Even with this more complex product portfolio, SULZER was able to maintain the higher yield level over the last several years.
SULZER have drawn the conclusion that, if they had started using MAGMA only one year earlier in 2007, they could have reduced the liquid metal demand by 160 t in order to manufacture 1690.45 t of raw parts (assuming a yield of 55.5%). Alternatively, it would have allowed them to increase production by 88.8 tons of castings, directly improving their turn-over and reflecting one month of their production.
In addition, SULZER could drastically reduce rework due to shrinkage porosity and surface defects. Another area where the simulation tool has helped tremendously is product development. This is especially true for the dimensioning of wall thicknesses and analyzing the manufacturability of their castings, widening SULZER's technological capacity and competitiveness. Today, a new design is first produced in the virtual world, offering the chance to make changes at early stages and take advantage of the corresponding cost savings.