Casting & Foundry

Manage heat number traceability, melt planning, die and mould life tracking, production scheduling, scrap analysis, and precise foundry costing through a single platform built for foundry operations.

Every Percentage Point of Yield Has a Cost

A foundry can meet its production target and still lose margin through excess alloy additions, metal loss, rejected castings, repeat fettling, pattern-related defects and energy consumed by an inefficient melt sequence. IEV brings demand, melt planning, material consumption, production, quality, traceability and finance into one foundry ERP system. Teams can see what each heat produced, where its yield was lost, which castings it became and what the final output actually cost while the information is still useful to the next pour.

ONE CONNECTED FOUNDRY FLOW

One Heat Record. The Full Production Story.

A customer order drives the melt plan. The melt plan determines charge requirements, furnace loading, mould and core readiness. The pour creates castings that move through fettling, treatment, machining and inspection before they can be dispatched. IEV keeps every stage connected through the same heat and production identity. Material issued to the furnace, output booked on the floor, defects recorded by quality and finished castings cleared for dispatch all update the same operational record, giving production, quality, stores and finance one version of what happened.

CASTING & FOUNDRY WORKFLOWS

See Where Yield, Quality and Margin Change

Customer Order to Melt Plan

Every customer order begins with a casting quantity, alloy specification, delivery date and process route. Before production can begin, these requirements must be translated into mould quantities, expected yield, metal demand, heat requirements and a workable furnace schedule.

IEV converts confirmed orders into a coordinated production and melt plan. Planners can group requirements by alloy grade, balance them against furnace capacity and align moulding, core making, pouring and downstream operations with the promised delivery date.

Customer, Casting, Alloy Grade and Delivery-Date-Wise Order Planning
Casting Quantity Conversion Into Mould, Metal and Heat Requirements
Yield-Based Gross Metal Requirement Calculation
Alloy Family-Wise Heat Consolidation and Furnace Scheduling
Mould, Core, Pattern and Material Readiness Checks
Production and Dispatch Commitment Monitoring

Charge Preparation to Chemistry Approval

Once the heat is planned, the required metal charge must be prepared using the correct combination of virgin metal, returns, scrap and alloy additions. Any difference between the planned and actual charge affects chemistry, yield and the final cost of the heat.

IEV records each material issued and consumed against the heat number. Chemistry results, corrective additions and approval status remain attached to the same heat record, giving production, quality and costing a complete account of what entered the furnace before pouring was authorised.

Planned and Actual Charge Mix Recording
Virgin Metal, Scrap, Returns and Ferroalloy Consumption
Heat Number Generation and Furnace-Wise Identification
Chemistry and Spectrographic Result Capture
Corrective Alloy Addition and Re-Test History
Heat Approval, Hold and Rejection Status Control

Moulding, Core Making & Pouring

Mould and core readiness must match the melt schedule. If tooling, sand preparation, cores or moulds are delayed, molten metal waits, energy is wasted and the production sequence begins to break down.

IEV coordinates pattern issue, core production, mould preparation and pouring against the planned heat. Teams can record what was prepared, which tooling was used and how much metal was poured into each casting batch, maintaining the production link from pattern to pour.

Pattern, Die and Core Box Issue and Return Tracking
Core and Mould Quantity Planning Against Production Demand
Moulding and Core-Making Progress Booking
Heat-to-Mould and Casting Batch Allocation
Pouring Quantity, Temperature and Time Recording
Mould, Core and Pouring Rejection Capture

Shakeout, Fettling & Secondary Processing

The pour is only the midpoint of the workflow. Castings still pass through shakeout, shot blasting, fettling, heat treatment, machining, surface treatment and inspection before they become dispatchable output.

IEV follows every casting batch through its defined routing. Good quantity, rejection, rework, process loss and pending work are recorded at each operation, showing where output is waiting and where yield is being lost after pouring.

Operation-Wise Routing and Production Progress Tracking
Shakeout, Shot Blasting, Fettling and Grinding Booking
Heat Treatment, Machining and Surface-Finishing Control
Internal and Subcontracted Process Tracking
Good Output, Rejection, Rework and Process-Loss Recording
Batch-Wise WIP and Pending-Operation Visibility

Final Inspection, Traceability & Dispatch

A casting cannot be treated as finished simply because processing is complete. It must meet dimensional, metallurgical and customer-specific requirements while retaining an unbroken record of the heat, material and operations behind it.

IEV connects final inspection and dispatch with the casting’s complete production history. Quality-cleared quantities can be allocated to the relevant customer order, while forward and backward traceability remains available from raw material receipt to final shipment.

Dimensional, Metallurgical and Final Inspection Recording
Accept, Hold, Reject, Rework and Deviation Status Control
Heat, Batch, Lot and Serial Number Traceability
Material, Process and Quality History by Casting Batch
Quality-Cleared Finished Stock Allocation
Customer Order-Based Packing, Dispatch and Documentation

BUILT FOR FOUNDRY OPERATIONS

Control the Variables Behind Every Good Casting

Melt Planning & Production Scheduling

Convert orders into heat, moulding, and finishing plans based on alloy grade, furnace capacity, and delivery priority. Group compatible requirements to eliminate avoidable changeovers and keep downstream operations moving constantly. Maximise furnace utilisation and ensure on-time delivery to customers, directly protecting your ongoing sales commitments.

Material & Sand Consumption Tracking

Record planned and actual charges for every heat, including virgin metal, scrap, alloys, and precise sand usage. Tie consumption directly to the heat to track grade-wise usage and prevent costs from disappearing into monthly totals. Accurate tracking stops material wastage from eating into your revenue margins.

Die, Mould & Pattern Life Management

Track the exact lifecycle, condition, and maintenance history of dies, moulds, patterns, and core boxes. Confirm tooling readiness before production and connect recurring casting defects directly to the specific tool used. Automating maintenance schedules for these critical assets extends their usable life and prevents unexpected production downtime.

In-Process Quality & Defect Control

Capture chemistry, process parameters, and defect observations against the exact heat, batch, and operation. Contain non-conforming output early and investigate defects using the actual, recorded production history. Isolating bad pours before they reach the machining stage reduces wasted labour hours and stops rejected batches from reaching clients.

Heat, Batch & Lot Traceability

Preserve heat, batch, and lot identity from pouring through to dispatch. Instantly trace any finished casting back to its exact material, process, and quality records without manual reconstruction. Rapid data retrieval accelerates compliance reporting and isolates the exact scope of required containment, safeguarding your vendor rating.

Foundry Job Costing & Variance Analysis

Compare planned output against good castings, scrap, rejection, and process loss. Pull exact material, energy, labour, and subcontracting data directly into job costing to see where margins are earned. Management gets a factual view of profitability per job, allowing you to quote future sales with guaranteed revenue margins.