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  1. 1 Right the st Time! Pacific Steel Casting Company Est. 1934

  2. Facilities Management of a Steel Casting Company Robert Murillo Pacific Steel Casting Company Facilities Manager March 8th, 2012

  3. Carbon Steel vs Cast Iron • Carbon content <2% • Steel is an alloy of iron, carbon, nickel, chrome, vanadium, etc… • Types: Low, Medium, High, and Ultra-High Strengths • Carbon Content >2% • Cast Iron is basically carbon, iron, silicon. • Types: Gray, White, Malleable, and Ductile.

  4. Pacific Steel CastingIn a Nut Shell • Plant 1 opened in 1934. • Plant 2 opened in 1975. • Plant 3 opened in 1982. • Each plant equipped with state of the art environmental controls. • 3 Carbon filtration systems to remove VOC from process. • Facility has the ability to demand 9+ Mega Watts during steel production. • Recycles over 2,000+ tons of scrap metal a month. • Recycles all process materials either internally or through outside vendors. • Largest industries serviced are Oil Tool and Industrial Trucking. • Combined plant production capacity of 2000+ tons/month.

  5. 3 Production Facilities Sand Molding Types: • Green Sand • Shell • Air-Set

  6. Overview of Steel Casting Production Process

  7. My Background • Completed trade school and became a Certified Welder. • Graduated Butte College with an AS Degree in Welding Technology. • Graduated CSUChico with a BS in Manufacturing Technology with a minor in Production Operations Management. • Worked through college as a Fabricator/Machinist. • Hired by Pacific Steel Casting in 2004 as a CAD operator. • Promoted to Robotics Engineer. • Promoted to Plant Engineer. • Promoted to Facilities Manager. • Professional Organizations- • American Welding Society (AWS) • Society of Manufacturing Engineers (SME) • American Foundry Society (AFS) • Steel Founders Society of America (SFSA) • Western Division Chairman • Awards and Achievements- • Westec College Challenge – Grand Prize • Technical Paper Published in Modern Casting Magazine ‘Minimizing Power Demand on Electric Arc Furnaces’.

  8. Facilities Management • Maintenance Departments • Operating Budget • Equipment Design and Engineering • Environmental Responsibility • Capital Equipment Installation/Project Management • CalOSHA Compliance • Safety/Technical Training • City of Berkeley • Energy Management • Facility Security

  9. Projects • EAF Dust Collector

  10. Projects • EAF Energy Demand Reduction

  11. Projects • LN8 Shot Blast Machine

  12. Continuous Improvement • Lean Manufacturing Implementation • 5S Projects • TPM – Total Productive Maintenance • Preventative Maintenance • Predictive Maintenance • Root Cause Analysis

  13. Quiz • What year did PSC first open for business? • What is PSC’s combined production capacity (tons)? • How much power demand does this facility require? • What does PSC call our VOC filtering equipment? • What are the two main industries PSC services?