PUTTING QUALITY IN THE RIGHT HANDS.

tQcij Grenville Castings Ltd.

OUR MISSION STATEMENT The primary focus of Grenville Castings Ltd. is to provide a workplace that offers all employees a sense of security and purpose. Each employee must be encouraged and

allowed to accept an element of the general overall responsibility of the company, and, in doing so, becomes

an integral part of a team capable of satisfying all the requirements of both shareholder and customer.

J.S. Dinsmore President

PROVIDING CASTING SOLUTIONS

Our modern facilities provide a comfortable, productive environment for our employees, which ensures the highest quality castings for our customers.

Permanent Mold Operation The operator removes the permanent mold casting from a steel die. In our cellular production, the permanent mold operator is responsible for melting his own aluminum, therefore eliminating the need for an independent melter. Monitoring of molten aluminum quality is done by thermal analysis (in background).

CELLULAR PRODUCTION: GETTING THE BEST FROM PEOPLE AND PROCESS.

Processing A casting is processed according to pre· determined standards by sawing and grinding.

At Grenville Castings Ltd., the key to our success is our people. In this people-first environment , everyone recognizes that quality is an individual responsibil ity.

In our on-going efforts to produce the finest castings in North America, we continue to develop our manufacturing operations on the cellular production method. For Grenville, it represents the perfect merging of three key components: quality, people, and process.

Cellular production provides signifi­cant benefits to our customers, including: • Dramatically improved quality

because casting deficiencies are immediately detected and corrected.

• Significant cost reduction due to the close coupled process.

• Reduction in lead time for deliveries because of efficient production cycle.

• Optimum SPC reporting due to de­tailed, written process control plans at each step in the production process.

The cell provides a pleasant We are committed to cellular

production. It allows us to produce castings with optimum flow in the

1. Permanent Mold; 2. Processing; ;3. Machining Center; 4. Pressure Testing Packaging; ;5. SPC/Packaging.

environment for our employees in both comfort and job satisfaction. The ventilation system provides clean,

shortest time in the smallest space. All parts of the process are incorporated into one self-contained area for immediate processing, cost effectiveness, and high quality.

cool air with a significant reduction in noise. Morale is high because cross training in all cell functions prevents job boredom, and promotes a dedication to producing zero defect castings.

Pressure Testing Packaging The operator utilizes go-no go jigs and 100% pressure testing to ensure that there

~~~i~i~~~i~t~~S~c data is compi led, and the castings are packed and audited for immediate shipping.

Machining Center This custom designed machining center uses datum target points in jigging the casting to ensure an accurate repeatable machined casting. The operator refers to the PCP

;i~~~~~~:us~c and chart to ensure a quality product.

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Safety Committee Our more than 325,000 hours without a lost time accident is a testament to our on-going efforts to provide a safe working environment for our people.

Grenville Casting's safety committee meets weekly to establish and oversee safety standards and develop training sessions. Safety is also promoted by annual safety bonuses to our employees.

President 's Advisory Committee The commitment to quality begins with a commitment to our employees. We want our people to have a sense of purpose and satisfaction to help us reach this goal. We developed the President 's Committee many years ago.

The committee is comprised of five employees who meet wi th the president monthly to discuss and formulate policy on every facet of operat ions, from wages and profitabi lity to capital investment and benefits.

Training Maintaining excel lence requ ires a commitment to training. Weekly training sessions are conducted in our training facility, and provide instruction on topics ranging from SPC and safety, to process controls and communicat ion ski lls for all employees.

OUR SUCCESS REVOLVES AROUND

QUALITY AND CUSTOMER SATISFACTION.

Shown is a sample of the low pressure and permanent mold castings produced in our plant:

First row: diesel engine Charge Air Cooler casting - low pressure process, 2.75 lbs. ; behind it is a marine flywheel housing - low pressure process, 10 lbs.; CAC casting - semi permanent mold process, 9 lbs. ; marine exhaust

collector - semi permanent mold process, 10 lbs.; desk support bracket - low pressure process, 3.5 lbs.

Back row: capacitor transformer -low pressure process, 63 lbs. ; flood light housing - low pressure process, 12 lbs.; capacitor voltage transformer - low pressure process, 180 lbs. (this is the largest low pressure casting made in this world).

Low Pressure Mold As the number one casting method at Grenville Castings, the low pressure process results in many cost savings and quality advantages. Low pressure presents a very high yield, in some cases as high as 99%. The minimal gating required reduces secondary cleaning. The casting also has much higher mechanical properties (often more than 20%). The working conditions are better since the operator is not exposed to a traditional molten aluminum environment .

Permanent Mold The operator (pictured right) places a ceramic fi lter into a mold in order to prevent aluminum oxides from entering a casting cavity, therefore ensuring a pressure tight part. Only primary aluminum is used in our casting operation . Our process provides us with an extremely low melt loss compared to industry standards.

Shell Core Machine Grenville Castings' fully automated shel l core machine produces shell cores for irregularly shaped internal areas of castings where loose pieces and pull ing cores cannot be adapted . Each core is produced, sealed for internal casting quality, and monitored according to specified quality standards.