Established in 1946, Cast Iron Welding Services (CIWS) have a wealth of experience in the gas fusion weld repair process of cast iron.

CIWS work predominantly in the marine and power engine industry. Their casting repair skills are in high demand for repair and for an increasing amount of heritage castings in the form of architectural, steam and vintage vehicle components. Typical problems dealt with are mechanical damage, fractures, erosion, and cracks.

Challenge

Many of the processes used by CIWS relied on storing paper-based documentation and manual entry. To make the operational processes more efficient and to improve the data flow within the organisation, they needed help to create new digital practices and procedures. Specifically they wanted to eliminate double entry of information and enable a smoother flow of data from the work floor to the Manufacturing Resource Planning system (MRP).

Solution

To help make CIWS more digital, they brought on a WMG intern - Clifford TsunguLink opens in a new window, an engineering graduate from De Montford University. The internship project initially was set up for 8 weeks to focus on four areas of improvement. These included;

• Developing web-based frontend interface for work floor to enter parts details
• Creating and maintaining a database to store the data
• Liaising with ProgressPlus (a MRP system that CIWS use to monitor and plan their production) to develop a detailed label system
• Creating a data display interface for the workshop to view activity progression

Clifford was able to overcome these challenges by developing a full-stack application to record and store data from the shopfloor as well as testing applications to understand and improve usability. The intern also worked with ProgressPlus, having technical discussions to develop a deeper understanding of the system. This enabled CIWS to maximise the benefits of the software and establish a more valuable relationship with the vendor for further work in the future.

Impact

By creating a digital application, CIWS no longer had to rely on any paper-based processes. This also achieved the initial goal of reducing double entry. The impact this had on resource was significant – the average data entry used to take approximately an hour, because of the new system it was reduced by 90% to just a matter of minutes.

In addition to reducing the time, it also enhanced the accuracy. Now that the in-house process connected directly to the MRP system this significantly reduced the likelihood of error.

By choosing to work with an intern instead of software consultants for this full-stack application CIWS saved up to 70% on costs. CIWS were so thrilled with the results of working with Clifford that they extended his stay for another month and are investing in an additional intern too.

“Having the additional resource has been such a huge help” commented Marie PalmerLink opens in a new window, Director of Cast Iron Welding Services “We knew that the processes we were using could be more effective, but didn’t have the time or capacity to review. Clifford has been such a valuable member of the team since he joined and we’ve gained so much from the WMG internship program”

Engineer, Shadman RafidLink opens in a new window, of WMG said “The improvements that Cast Iron Welding Services have made to their processes have been incredibly impressive. Not only have they revolutionised their paper-based procedures but the overall time and money saved will have long-lasting effects”

For more information on working with WMG or joining the WMG Internship Programme, please email wmgsme@warwick.ac.uk