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Waupaca Foundry, Inc.

P.O. Box 249, 54981 Waupaca, WI
1955 Brunner Drive, 54981 Waupaca, WI
USA

Hall map

NEWCAST 2019 hall map (Hall 14): stand D36

Fairground map

NEWCAST 2019 fairground map: Hall 14

Contact

Carsten Behrensmeier

Manager Sales and Marketing

Germany

Phone
49.211.16009.793

Email
Carsten.Behrensmeier@waupacafoundry.com

Jamie Bolton

Director of Sales

USA

Phone
1.317.578.5501

Email
jamie.bolton@waupacafoundry.com

Our range of products

Product categories

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.01  Material groups
  • 01.01.001  Grey cast iron

Grey cast iron

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.01  Material groups
  • 01.01.002  Spheroidal graphite cast iron

Spheroidal graphite cast iron

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.01  Material groups
  • 01.01.005  Austenitic-ferritic cast iron with spheroidal graphite (ADI)

Austenitic-ferritic cast iron with spheroidal graphite (ADI)

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.03  Customers and uses for iron, steel and malleable castings
  • 01.03.030  Agricultural machinery

Agricultural machinery

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.03  Customers and uses for iron, steel and malleable castings
  • 01.03.032  Machinery construction (general)
  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.03  Customers and uses for iron, steel and malleable castings
  • 01.03.040  Pumps and compressors

Pumps and compressors

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.04  Examples of cast products
  • 01.04.012  Brake drums and discs

Brake drums and discs

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.04  Examples of cast products
  • 01.04.024  Housings

Housings

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.04  Examples of cast products
  • 01.04.026  Transmission components

Transmission components

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.04  Examples of cast products
  • 01.04.030  Boiler components

Boiler components

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.04  Examples of cast products
  • 01.04.032  Hydraulic castings

Hydraulic castings

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.04  Examples of cast products
  • 01.04.050  Crankshafts

Crankshafts

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.04  Examples of cast products
  • 01.04.068  Camshafts

Camshafts

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.04  Examples of cast products
  • 01.04.087  Rail vehicle components

Rail vehicle components

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.04  Examples of cast products
  • 01.04.095  Flywheels

Flywheels

  • 03  Services
  • 03.06  Secondary treatment/Machining
  • 03.06.001  Heat treatment

Heat treatment

  • 03  Services
  • 03.06  Secondary treatment/Machining
  • 03.06.002  Mechanical machining

Mechanical machining

  • 03  Services
  • 03.06  Secondary treatment/Machining
  • 03.06.003  Coating, priming, painting

Coating, priming, painting

Our products

Product category: Machinery construction (general)

Custom Iron Casting Solutions for Light Vehicle Engine

Providing Real Value for Our OEM Partners
At Waupaca Foundry, our expertise gives our customers a competitive edge. Our casting engineers have a track record of providing design and manufacturing solutions that deliver tough, lightweight cast iron engine components for passenger vehicles and light trucks. Our tooling, drafting and core making engineers put decades of experience to work for you—we go beyond just meeting specifications to delivering consistent value.

Iron Casting Services for Engine Components
For new components or improvements to existing parts, trust Waupaca Foundry to meet your specifications. Major global brands trust Waupaca Foundry for keen attention to VA/VE processes delivering quality iron castings such as crankshafts, flywheels, brackets, bearing caps, pulleys, fuel rails, balance shafts, oil pumps and water pumps.

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Product category: Machinery construction (general)

High-Strength Cast iron Suspension Components for Light Vehicle


Consistent, High-Quality Iron Castings for Passenger Vehicle and Light Truck Iron Castings
Consistency in iron castings is a result of proven expertise in metallurgy, production processes, and service—everything that has made Waupaca Foundry the first choice of top light vehicle OEM's. Our casting engineers have a track record of providing design and manufacturing solutions that deliver tough, lightweight castings for passenger vehicles and light trucks. Our tooling, drafting and core making engineers put decades of experience to work for you—we go beyond just meeting specifications to delivering consistent value.
 
Passenger vehicle and light truck OEM's depend on Waupaca Foundry to deliver durable, competitively priced high strength disc brakes, knuckles and control arms that give a competitive edge.
 
Light Vehicle Suspension Component Iron Castings
Your vehicle suspension systems depend on high performance from ductile and gray iron castings. At Waupaca Foundry, we deliver that durability for a full range of passenger vehicle and light truck suspension components including brake rotors, knuckles and control arms.
 
We support automotive manufacturers across the globe from state of the art manufacturing facilities located in various parts of the United States. Our locations employ the best technology, the most experienced foundry men & women, and a commitment to collaborative, innovative iron casting design & production. We take pride in reducing costs, increasing quality and decreasing time to market.
 

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Product category: Machinery construction (general)

High-Strength cast iron Brake Components for Light Vehicle

Making Your Passenger Cars and Light Trucks better
Our brakes are stopping vehicles worldwide. Top manufacturers trust Waupaca Foundry cast iron brake components to deliver superior performance and lasting strength.

At Waupaca Foundry, our business is built on delivering OEM's both quality and value based pricing for passenger cars and light trucks. Expert process engineering and technical superiority of advanced melting technology and finishing systems produce consistently high quality gray iron and ductile iron castings. Our customized foundry technology is engineered for speed and our experienced teams produce iron casting design solutions that enhance brake component quality and life cycle.

Waupaca Foundry's Brake Component Services
Extensive industry experience and highly-developed melting, casting and machining facilities enable us to meet the requirements of multiple light vehicle manufacturers world-wide. Over the years, our customers trust us to manufacture light vehicle brake components including brake rotors, brake calipers, brake anchors, performance brakes, wheel hubs and brake drums.

At Waupaca Foundry, we offer a full range of metal casting solutions for light vehicle brakes, engines, suspensions, and drivelines.

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Company news

Date

Topic

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Apr 24, 2019

WAUPACA FOUNDRY OPENS MACHINING OPERATIONS, FACILITY FEATURES ROBOTIC INNOVATION

Waupaca Foundry, Inc., a Hitachi Metals group company, announces it is opening a machining operation adjacent to its gray iron foundry located on the east side of Waupaca. The new Waupaca Foundry machining plant is located at 600 Industrial Drive, Waupaca, Wis., and will machine brake components for the commercial vehicle market.

The facility has 50,000 square feet of manufacturing space and will initially employ 15 skilled workers who lead CNC machining of cast iron components produced at Waupaca Foundry. This is a second machining operation for Waupaca Foundry, which also operates a machining facility located in Effingham, Illinois. The decision to expand operations beyond raw castings was to support customer demand.

“Our global markets are changing and customers want a higher level of value-added services,” said John Wiesbrock, executive vice president for Waupaca Foundry. “A vertically integrated model such as this takes the waste out of the supply chain for customers.”  Wiesbrock added opening this facility fulfills corporate objectives established in 2016 to vertically integrate services. 

Braking components machined in the new facility will be used by heavy duty truck manufacturers. These components are cast and machined on site in Waupaca rather than shipped to Tier 1 suppliers. However, Wiesbrock adds that opening the machining operation will not eliminate the need for other supply chain partners providing machining services.

The facility is managed by Jason Grasman, who has nearly 20 years of experience in the machining industry. He says expanding services to include machining gives customers a level of quality they have come to expect from Waupaca Foundry and streamlines the supply base.

“We provide a ‘one-stop shop’ for component production,” Grasman said. “Customers could potentially have a casting supplier, a machining supplier, and a coating supplier for one part. Complexity in the process increases with each supplier you add, so this makes it much more convenient for our customers.”

The new facility features innovations in modern manufacturing designed to automate production and provide ergonomic advantages for employees.

  • Robots unpack and pack parts onto skids to reduce the potential for repetitive injury to workers because employees are not handling the components manually.
  • Smaller robots called automated guided vehicles (AGV) are programmed with maps of the facility and transfer all parts to one of three machining cells.
  • State-of-the-art inverted, twin spindle CNC lathes produce consistently tight tolerance, high quality components.
  • Waupaca Foundry will recycle iron chips machined from the castings and re-melt for use to make new iron castings.
“Some of the parts we cast for large semi-trucks and buses weigh more than 80 pounds,” Grasman said. “When we machine parts this large to meet customer specifications, we can easily re-melt the chips at the foundry.”

With the opening of the machining facility, Waupaca Foundry now operates five production facilities in Wisconsin where it is headquartered.

For more information on Waupaca Foundry please visit www.waupacafoundry.com.
For more information on Hitachi Metals please visit  www.hitachi-metals.co.jp/e/. 

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Aug 8, 2018

WAUPACA FOUNDRY EARNS QUALITY AWARD, RECOGNIZED BY FIAT-CHRYSLER

For the second consecutive year, Waupaca Foundry has received the 2017 Outstanding Quality award from Fiat Chrysler Automobiles (FCA). Waupaca Foundry was one of 73 global suppliers to receive this award out of more than 2,500 suppliers and was the only foundry recognized. Waupaca Foundry has supplied iron castings to Fiat-Chrysler since 1999 including crankshafts used in automotive powertrains.

Fiat-Chrysler presented this award to recognize top-level performance and a dedication to excellence from suppliers that meet these qualifications:
  • Supplier production is analyzed for 11 consecutive months,
  • Suppliers must achieve scores of 100% on warranty and incoming material quality,
  • Suppliers go above and beyond expectations.
"Our continued commitment to process improvement is driving direct results for our customers," said Cody Rhodes-Dawson, plant manager for Waupaca Foundry. "We are ranked according to exacting standards of quality, reliability, and consistency to guarantee performance in our customers' products." 

In the last 18 months, Waupaca Foundry locations have received top supplier status from several customers:
  • In spring of 2018, Toyota Industrial Equipment Manufacturing honored Waupaca Foundry for professional excellence and development in casting parts for its products. Waupaca Foundry is the first Tier II supplier awarded the Professional Excellence Award.
  • The Tell City, Indiana plant earned Q1 Certification from Ford Motor Company. The achievement confirms Waupaca Foundry consistently delivers high-quality products on time to Ford customers and Q1 certification is a milestone in the pursuit of quality.
  • Kawasaki Motors Manufacturing Co. honored Waupaca Foundry with Kawasaki's 2017 Environmental Stewardship Award, the company's fourth award from the engine maker since 2011.
Waupaca Foundry credits its production management system called "Waupaca Way" which engages all employees in continual improvement of casting quality, production efficiency, customer service, and on-time delivery.

"We are proud of all our team who embrace our commitment to continual improvement to reap results for our customers," said Mike Nikolai, President, COO and CEO of Waupaca Foundry. "Expected outcomes for our customers are high quality and high satisfaction and it's rewarding when our team is recognized for their effort."

For more information on Waupaca Foundry please visit www.waupacafoundry.com.
For more information on Hitachi Metals please visit  www.hitachi-metals.co.jp/e/. 

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