Engineering &
Reliability
We maximize machine operational availability, eliminate unplanned downtime, and redesign processes for maximum throughput and product consistency in aluminum melting, casting, and extrusion facilities.
Maximizing Uptime and Process Stability
Every unplanned downtime event is a solved problem waiting to happen. Our engineering and reliability team diagnoses the root causes of equipment failure and process instability — then builds the systems to prevent them permanently.
- Continuous improvement of machine operational availability (OEE)
- Reliability-centered maintenance (RCM) program design and implementation
- Metallurgical process analysis and alloy optimization
- Equipment failure analysis and Failure Mode & Effects Analysis (FMEA)
- Furnace performance assessment and heat treatment optimization
- Casting and extrusion die engineering and performance improvement
- Predictive maintenance program development (vibration, thermal, oil analysis)
- Spare parts strategy and critical inventory optimization
Our reliability engagements consistently deliver significant OEE improvements by targeting the availability, performance, and quality losses most impactful to your specific facility.
Our Engineering & Reliability Practice
Reliability-Centered Maintenance
RCM analysis to determine the most effective maintenance strategy for each asset — eliminating unnecessary PM while ensuring critical equipment never fails unexpectedly.
Furnace & Heat Treatment
Combustion system optimization, refractory assessment, temperature uniformity surveys (AMS 2750), and heat treatment process development for aluminum alloys.
Metallurgical Analysis
Microstructural analysis, alloy chemistry optimization, heat treatment metallurgy, and process-property relationships for casting and extrusion products.
Predictive Maintenance
Vibration analysis, thermographic inspection, oil analysis programs, and ultrasonic testing to detect developing failures before they cause unplanned downtime.
FMEA & Failure Analysis
Design FMEA, process FMEA, and physical failure analysis (fractography, SEM/EDS) to eliminate recurrence of catastrophic failures and chronic reliability issues.
Die Engineering Support
Casting die design review, thermal analysis, die life improvement programs, and extrusion tooling optimization to reduce tooling costs and improve product quality.