Customer-Centric Improvements Fuel Sustainable Growth
Since 1946, Stainless Foundry & Engineering (SF&E) has been committed to delivering high-quality pump and valve components while prioritizing our customer success. Our customer-centric philosophy is built on proactive communication, innovative problem-solving and an unwavering dedication to continuous improvement.
This mindset drives not only how we engage with customers but also how we invest in cutting-edge foundry operations, develop our workforce and position ourselves for sustainable growth well into the future. At SF&E, we understand that customer success depends on precision, dependability and partnership—and we’re here to deliver.
The number of industries relying on castings for pumps and valves continue to expand, and the volume of demand within each industry continues to grow. At the same time, the U.S. foundry landscape faces consolidation—making trusted partnerships more essential than ever. A customer-focused approach is more holistic than it sounds – not only does it strengthen client relationships, it has proven to enhance our workplace culture and consistently elevate the quality of our production.
Strive for Strong Customer Relationships
In today’s digital age, SF&E recognizes that outdated, passive foundry-customer relationships are no longer acceptable. Foundries are a key link in the supply chain and must deliver the same level of transparency and responsiveness customers expect from all their suppliers.
Over the past 10 years, we have incrementally modernized our communications to ensure we remain a proactive partner fully invested in our customers’ success. SF&E provides an online portal for real-time project updates, ensures our customer service team is always accessible, and offers expedited services when needed. We communicate openly about project changes and their implications, and our internal processes prioritize immediate and seamless communication. Our goal is to match each customer’s need for agility, accountability and results-driven collaboration.
A customer-focused approach also includes problem solving at the beginning of a process so that production runs as smoothly as possible. Recently, SF&E began work with a new customer part. The customer could only provide the part and a set of 2D drawings that dated back 10-15 years, which were unfortunately too old to be reliable.
The SF&E engineering team combined old school hand-drawn pattern making knowledge with their MAGMASOFT® technical acumen and some reverse engineering to build a 3D model of the part they needed. We used trial and error to test and validate the model and, from there, were able to replace the outdated pattern and begin production.
Continuous Improvement to the Work Environment
Our commitment to investing in our employees and in new technology increased in 2024 for both employee training and capital expenditures to target a safer, more productive work environment that produces high quality parts.
One example is an investment in a Triplex state-of-the-art waterblast system. This advanced technology streamlines the removal of ceramic shells from investment castings, delivering cleaner castings with smoother, damage-free surfaces. The process reduces labor and inspection time by 10–20%, freeing up space in cleaning areas and enabling employees to contribute more effectively across the production floor—a clear operational win.
The benefits extend beyond productivity. Traditional knockout hammers, previously a significant source of noise and airborne silica, have been replaced. The waterblast system contains silica particles within its closed cabinet, significantly improving air quality and eliminating disruptive noise. This not only enhances employee safety and health but also fosters a quieter, more focused work environment.
A second example is the multi-phase throughput improvement project SF&E completed a few years ago, which has driven significant operational gains. Phase 1 focused on shifting the production floor from a batch mentality to single-piece flow, and Phase 2 introduced a dedicated finishing cell to eliminate equipment sharing and reduce bottlenecks.
Before the throughput improvement project, parts moved in batches, causing extended processing times and equipment sharing led to queues, stalling production. The SF&E operations team identified these inefficiencies and restructured the flow. Instead of batch processing, we now use smaller lot sizes based on furnace capacity and product families. Equipment is organized into specialized cells, with employees cross-trained to handle multiple tasks. This eliminates idle time and ensures smoother workflows.
The new finishing cell, located near heat treat and shipping, incorporates dedicated equipment for blasting, inspection, and packaging, streamlining the final steps before shipment. This setup not only reduces work-in-process inventory but also increases throughput by eliminating bottlenecks that cause delays. The impact was immediate: what was once a 4-person process involving significant idle time is now an operation for just two employees. The result? Faster cycle times, improved efficiency, and higher capacity to meet customer demands, all while enhancing employee productivity and safety.
The Metallurgical Difference
The SF&E metallurgical department is a key asset and with three degreed metallurgists on staff, we have a competitive advantage when it comes to technical knowledge. The department offers expert guidance on alloy properties, selection, applications and specifications. SF&E pours over 250 alloys for sand and investment castings. When standard grades fall short, our team can customize alloys to meet specific needs.
Our Metallurgical Testing Laboratory features on-site chemical analysis, state-of-the-art quality testing and inspection tools and capabilities for group discussions using a closed-circuit TV system. When additional resources are needed, we partner with approved independent laboratories to extend our capabilities, ensuring the highest level of accuracy and dependability.
As industries evolve and challenges in the foundry sector intensify, SF&E remains steadfast in our commitment to being a reliable partner for our customers. SF&E, customer focus isn’t just a philosophy — it’s the foundation of our sustainable growth and the key to driving success for the industries we serve.
If you are looking for a foundry partner that prioritizes customer relationships, a safe work environment and continuous improvement, contact us today.