In the competitive world of automotive diecasting, where precision and efficiency define success, reducing scrap while maintaining top-notch quality is a constant challenge. Recently, one major diecaster producing over 300,000 components annually made headlines by achieving a remarkable 52% scrap reduction. This was possible because the group had adopted Monitizer | PRESCRIBE, Norican Group’s AI-driven solution designed to optimize casting processes on virtually any manufacturer’s machines. This agnostic approach allows the technology to improve all foundry processes, to the producer’s advantage.
In diecasting, scrap is not just a waste of materials; it’s a direct hit to profitability. Beyond the material losses, scrap also consumes energy, time, and labor, and negatively impacts production schedules. This particular diecaster had seen significant growth over the preceding years, but scrap rates remained a persistent bottleneck.
“Reducing scrap is more than just cost-saving,” explained Steven Li, aluminum project director at Norican Technology’s ItalPresseGauss. “The customer wanted to take their already robust systems to the next level with a solution that could optimize every aspect of their process.”
AI in action
The diecaster worked closely with Norican’s Monitizer team to leverage the powerful Monitizer | PRESCRIBE platform. This AI-powered solution combines decades of foundry expertise with cutting-edge technology, offering a tailored approach to process optimization. The process began with Monitizer | DISCOVER ingesting historical data from the diecaster’s systems and additional sensors installed across the production line. By correlating this data with quality outcomes, the AI model identified the intricate relationships between mutually dependent variables in high-pressure diecasting (HPDC.)
“Monitizer | PRESCRIBE stands out because it’s not just about data collection. It’s about actionable insights,” Li said. “It tells operators exactly what to adjust and when, turning complex processes into manageable steps.” The AI model provided real-time recommendations on machine settings to optimize outcomes, such as die temperature, shot duration, injection pressure, and more. Operators received these prescriptions through an intuitive dashboard, ensuring the solution was as user-friendly as it was powerful.
The impact was profound. In just one production batch, Monitizer | PRESCRIBE helped the diecaster reduce its average scrap rate by 52%, and now it’s helping to maintain that performance. “If these results are replicated across all products, the customer stands to save over $100,000 annually in scrap costs alone,” Li noted. “Add in the energy savings and productivity gains, and the return on investment is undeniable.”
The diecaster’s results extended the successes recorded by other metalcasting operations, including Grede Holdings LLC’s implementation of Monitizer | DISCOVER across its foundries. Mike Meyer, vice president of Operations reported: “Our sand processes involve 2,700 variables—an impossible task with spreadsheets. Only with AI can we unlock optimization at a level never seen before.”
Grede sought digital solutions to also address a pressing challenge: the loss of seasoned expertise as experienced workers retired.
“In order to handle that staff turnover, you have to rely more on technology and digitalization, pulling your best people’s know-how into your systems and your software,” said Susan Bear, Grede’s Chief Technology Officer.
What distinguishes the Norican Group IIoT solution is its ability to integrate seamlessly with existing systems, minimizing the need for additional infrastructure investments. The Monitizer platform is compatible with various types of foundry equipment, making it a versatile choice for businesses looking to upgrade their processes without overhauling their set-ups.
“The implementation challenges were mainly in the different IT architectures used across our different plants,” recalled Grede’s IoT process and control lead Matt Deyarmond. “Thankfully Monitizer is very good at handling many different communications protocols, its ease of integration is a real strength.”
“Monitizer | PRESCRIBE isn’t just about fixing problems,” Li continued. “It’s about anticipating them. By predicting and preventing defects, it delivers stability and consistency.”
This forward-thinking approach not only improves quality but also enhances sustainability by reducing energy consumption and waste, critical considerations as industries face increasing regulatory and consumer pressures.
The AI frontier
As AI is more widely adopted by metalcasters, its potential to revolutionize operations is clear. From reducing scrap and stabilizing processes to empowering less experienced operators, digital solutions like Monitizer are setting a new standard for excellence.
“Whether it’s high-pressure diecasting or sand systems, AI-driven solutions like PRESCRIBE are transforming the way we approach manufacturing,” Steven Li summed it up. “It’s not just about making products. It’s about making them better, faster, and with less waste.”