Main Epcor Foundries 2015_w_images_v5_11-23-2015

EPCOR FOUNDRY DIVISION OF SEILKOP INDUSTRIES, INC.Serving The Aluminum Foundry Industry Since 1946

ISO/TS 16949:2009 Certification


SEILKOP INDUSTRIES, INC.

• Total Employment 125– EPCOR Foundry

• Production & Prototype Aluminum Castings

– HITECH Shapes & Designs• Production & Prototype Foundry Tooling

– A-G Tool & Die• Sheet Metal Stamping Dies

– Hamilton Precision• Roll Repair and Burn & Grind Operations

http://epcorfdy.com

http://epcorfdy.com


EPCOR FOUNDRYDivision of Seilkop Industries, Inc.

• Founded 1946• 57 Employees • ISO/TS 16949:2009 Certified• Building: 40,000 Sq./ft. • Aluminum Alloys Poured:

• 319• 356 • 357• 535 (Limited Only)

http://epcorfdy.com


EPCOR FOUNDRY Division of Seilkop Industries, Inc.

MAJOR CUSTOMERS• American Metal Technologies: Ford, International• Dover Corporation: Knappco, Civacon, OPW, Sure Seal• Eaton Corporation: Ford, GM, BMW, Jaguar• Pure Power Technologies: International• Skilled Manufacturing: GM• Pierburg: International • Idex Corporation: Warren Rupp• TSM Corporation: GM• Magna Powertrain (ICD): GM

http://epcorfdy.com


INDUSTRIES SERVED• Automotive• Heavy Truck• Aftermarket Automotive• Fueling Components• Bulk Handling• Pump Components• Air Movement


http://epcorfdy.com


2014 SALES BY INDUSTRY

Automotive65%

Air Movement3%

Aftermarket Auto.4%

Pump8%

Other2%

Marine1%

Heavy Truck8%

Fueling Comp.2%

Food1%

Electrical2% Decorative

1%Bulk Handling

3%

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MOLDING PROCESSES

• High Speed Automatic Green Sand Molding

– DISA Match 130 Horizontal Auto Line • 20” X 24” Flask Size• Automatic Core Setting

– Roberts Sinto FBO III Horizontal Auto Line • 20” X 24” Flask Size


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MELTING/POURING PROCESSES

• Combination Wet Bath/Dry Hearth Furnace 3,000 Lbs./Hr. (356 Alloy)

• Wet Bath (Re-Verb.) Furnace 3,000 Lbs./Hr. (319 Alloy)• Wet Bath (Re-Verb.) Furnace 2,200 Lbs./Hr. (319 Alloy)• Dry Hearth Furnace 1,200 Lbs./Hr. (356/357 Alloy)• Crucible Style Batch Furnace (All Alloys)


http://epcorfdy.com


AUTOMATED PROCESS CONTROLS

• PLC based monitoring and control of the following processes:– Sand System: Screening, aeration, and additions– Knockout: Job specific pressure and timing controls– Automated 5-axis CNC saw and trim cells– Shot blast: Part specific parameters for consistent

finishing


http://epcorfdy.com



WE SPECIALIZE:• Reduced lead times• Reduced tooling and launch costs• Increased design and process

development efficiency• Increased first time throughput• Increased quality throughout

program life

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EPCOR FOUNDRY Core Assemblies

• 8 Cores• 319 Alloy• 4.0mm wall thickness• Pressure Tightness: leak

rate of 1.5cc @ 20 psi

Shelby GT 500 Oil Filter Adapter

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EPCOR FOUNDRY Complex Core Assembly

Oil Filter AdaptersEngine Cylinder

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EPCOR FOUNDRY Oil Filter Adapters

Challenge:

• A major automotive Tier 1 supplier required an emergency replacement.• Parts with complex core packages &

challenging leak specifications were causing failures that exceeded 20%.

Epcor Solution:

• Epcor used existing tooling to maintain supply while engineering reviewed part.

• Simulation software was used to review and correct areas of concern.

• Epcor designed & built new tooling; justified via price reductions.

• First time throughput now exceeding 99%.

http://epcorfdy.com


EPCOR FOUNDRY Water Pumps

Challenge:

• A Tier 1 auto supplier required emergency resourcing with adaptation of existing tooling, core boxes, and dedicated trim tooling.

Epcor Solution:

• Epcor reverse engineered, re-gated, and reused original tooling from storage.

• Simulation confirmed gating redesign.• Maintained compressed launch timing.

http://epcorfdy.com


EPCOR FOUNDRY Turbo Inlets

Challenge:

• Customer required 8 sets of patterns, core boxes, and PPAP in 6 weeks.

Epcor Solution:

• Using tooling developed in-house, Epcor launched (8) part numbers for this program as well as (6) others simultaneously, and on-time!

• Thin wall casting construction.• Improved OEM design to improve

castability at Epcor and machinability at Tier 1 supplier.

http://epcorfdy.com


EPCOR FOUNDRY Intake Manifold Components

Challenge:

• Tier 1 machining facility experienced high levels of scrap (post machining) due to porosity and leakers.

Epcor Solution:

• Epcor developed a gating system to reduce turbulence and oxide entrapment.


EPCOR FOUNDRY EGR/ Water Crossover Components

http://epcorfdy.com

Challenge:

• New component design required complex core package (15 cores).

• Part cost estimates greatly exceeded customer budget.

Epcor Solution:

• Epcor aided in the re-design of component for reduction in complexity & cost.

• Project was delivered on-time and under budget.


EPCOR FOUNDRY Supercharger Housing Components

http://epcorfdy.com

Challenge:

• Shrink porosity caused by heavy wall sections.

• Leakers caused by porosity.

Epcor Solution:

• Epcor designed tooling to cast a chill into the rotor core allowing heavy sections to solidify without shrink porosity and eliminated leakers.


EPCOR FOUNDRY Thermostat Housing Components

http://epcorfdy.com

Challenge:

• Originally supplied plastic components began failing in the field.

• Design and material change threatened production shutdown.

Epcor Solution:

• Epcor used its in-house pattern design and build facility to compress timing.

• Exceeded customer requirements for delivery of PPAP samples in 4 weeks.


EPCOR FOUNDRY Fueling Components

http://epcorfdy.com

Challenge:

• 50% post machining scrap from the former supplier caused the customer to miss deadlines and lose business.

Epcor Solution:

• Epcor designed an in-mold filtration system ensuring clean metal throughout the pour, reducing porosity.

• Scrap was reduced by over 95%.


EPCOR FOUNDRY Miscellaneous Components

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EPCOR FOUNDRY Pump Components

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EPCOR FOUNDRY Water Outlets Components

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EPCOR FOUNDRY Brackets

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EPCOR FOUNDRY Miscellaneous Components

http://epcorfdy.com



http://epcorfdy.com



PRESIDENT/CEO: – Ken Seilkop: [email protected] – Cell: 513-615-6752

VICE PRESIDENT SALES AND MANUFACTURING:– Dave Seilkop: [email protected]– Cell: 513-615-1665

Senior Sales Engineer:– James Walsh [email protected]– Cell: 513-312-4211

http://epcorfdy.com

EPCOR FOUNDRY425 W. NORTH BEND RD. CINCINNATI, OH 45216PHONE: (513) 761-1035 FAX: (513) 761-0368


mailto:[email protected]



Main Epcor Foundries 2015_w_images_v5_11-23-2015

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