Grede Sees Scrap Reductions Across All Nine North American Foundries with Monitizer | DISCOVER

Grede, a leader in the foundry industry, is implementing cutting-edge IIoT technology at all nine of its North American foundries. Partnering with Monitizer, Grede aims to digitalize production and enhance quality control. Early results show every foundry running the new system has reduced scrap rates, delivering substantial cost savings.

Grede serves the automotive, heavy truck, and industrial sectors with nine foundries and three machining centers across the U.S. In 2020, digitalization became a strategic priority, driven by the need to maintain consistent quality amidst changing industry conditions. “We’re moving from the art of the foundry to the science of metalcasting™,” says CEO Cary Wood.

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Harnessing Expertise for Optimal Performance

The Monitizer platform was selected for its comprehensive foundry expertise, developed by specialists from DISA, Simpson, Wheelabrator, and more. "Simpson has been a trusted partner in our journey," notes Susan Bear, Grede’s CTO. "Their knowledge of sand processes, coupled with Monitizer’s real-time data and analytics, gives us a comprehensive solution for both sand and equipment optimization."

With Monitizer, Grede connects and monitors its sand systems, including Simpson Hartley and Multi-Cooler equipment. The platform provides real-time visibility, allowing operators to address issues before they impact quality. Additionally, the intuitive dashboards simplify plant-wide monitoring and align KPIs across all facilities.

Initial Success

Initial successes include significant scrap reduction and improved operational efficiency across all sites. “One foundry cut scrap by 50% just by optimizing sand inclusions,” says Susan. “Simpson’s role in delivering accurate sand control data has been pivotal.”

As Grede continues its digital transformation, it plans to leverage AI through Monitizer | PRESCRIBE for further process optimization. “The AI capabilities will allow us to tackle the 2,700 variables in our green sand foundries, which is impossible with spreadsheets,” explains VP of Operations Mike Meyer.

This collaboration marks a significant step forward in making smarter decisions based on real-time data, with Simpson and Monitizer playing crucial roles in Grede’s success story.

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