# Lynchburg Foundry

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Lynchburg Foundry
Lynchburg Foundry: The Ductile Dilemma

Understanding the Numbers: 1. Study Exhibits 1, 2, and 3 and answer the following: a. What is the per ton cost of ductile iron casting at the Lynchburg Plant? At the Archer Creek Plant? At the Radford Plant?

Lynchburg Plant | Archer Creek Plant | Radford Plant | \$194.91 | \$189.25 | \$222.05 |

b. What percentage of ductile iron can be recycled (i.e. ductile iron return that is generated) from each charge at the Lynchburg Plant? At the Archer Creek Plant? At the Radford Plant?

Lynchburg Plant | Archer Creek Plant | Radford Plant | 900 lbs. | 1840 lbs. | 600 lbs. |

c. What is the average percent of ductile iron return in the total raw material used in a 2,000 lb. charge at the Lynchburg Plant? In a 4,000 lb. charge at the Archer Creek Plant? In a 5,000 lb. charge at the Radford Plant? Lynchburg Plant | Archer Creek Plant | Radford Plant | 45 % | 46% | 12% |

d. What is the minimum amount of ductile iron return that can be used for the charge mix for castings? (from the reading) * Melting supervisors at the Lynchburg and Archer Creek plants determined that 40% ductile iron return was the minimum that each charge mix should posses.

e. What is the maximum amount of ductile iron return that can be used for the charge mix for pipe-making? (from the reading) * There is only about 16% ductile iron return available for the pipe making charge.

2. Examine Exhibit 5 and answer the following: f. Which plant generates the most ductile iron return? Explain how the Ductile Iron Return tonnage was calculated for each of the three plants.

The Lynchburg Plant generates the most Ductile Iron Return. Ductile Iron Return is calculated by: * Dividing the Estimated pouring weight by the tonnage necessary to necessary for each plant charge (i.e. Lynchburg 2000lbs = 1 charge, ( 84,000 /1 = 84,000 charges) * Multiply the

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