As we mark Bingham & Taylor's 175th year of innovation, we have been honored with the prestigious Plant Engineering Award by the Engineering Division of the American Foundry Society (AFS). This recognition is a testament to our team's dedication to advancing technology and sustainability in our Culpeper, Virginia foundry. This award highlights our commitment to excellence and ability to push the boundaries of engineering and manufacturing amidst challenging times.
Our project embarked on a transformative journey, overhauling decades-old technology to install state-of-the-art equipment and processes at our Culpeper foundry. Amidst the global challenges posed by the COVID-19 pandemic, our team executed a multi-phase upgrade that optimized every aspect of our foundry operations, from melting to assembly.
Maintaining product quality and consistency is paramount in our industry, and we understand that these factors are critical to our customers. Our foundry transformation was strategically designed to enhance these aspects, ensuring that each product meets rigorous standards of quality and consistency. Moreover, the efficiency improvements from our project have significantly reduced lead times, boosting our on-time delivery rate to an impressive 94%. These enhancements ensure that we continue to meet and exceed customer expectations in every facet of our service.
Technological Upgrades: Two 4MT Electric Induction (EI) Furnaces were introduced, replacing the older Cupola furnaces, to facilitate continuous molten metal flow. These furnaces not only increased our melting capacity fourfold but also dramatically enhanced our energy efficiency.
Infrastructure Innovations: We installed an innovative monorail system for seamless metal transport across the foundry and a new Melt/Quality lab for expedited in-house testing.
Process Enhancements: The entire assembly operation was upgraded to include advanced CNC machines, robotic welding, and laser cutting technologies, significantly boosting our production capacity, and reducing lead times by 65%.
Operational and Environmental Impact: The reimagined foundry operations have led to remarkable improvements in efficiency and environmental performance:
Increased Productivity: Our foundry achieved a 94% on-time delivery rate and introduced a second production shift, enhancing output and workforce utilization.
Reduced Environmental Footprint: We have seen a 93% reduction in particulate matter emissions per ton of metal melted, eliminated various harmful emissions (VOCs, CO, SOx, and NOx), and transitioned from Title V to Synthetic Minor Status due to our lowered emissions.
Waste Reduction: Our operations now generate 63% less slag per ton of iron melted and 99.6% less particulate filtrate monthly compared to fly ash generated by the old Cupola process.
Safety and Health Improvements: One of the most significant impacts of our transformation has been on the safety and health of our workforce:
Enhanced Safety Measures: The implementation of new equipment and processes helped achieve a 73% reduction in Total Recordable Incident Rate (TRIR) and an 81% reduction in Days Away Restricted Time (DART), with injury rates now four times lower than industry averages.
Healthier Work Environment: With the introduction of automatic lining equipment and significant reductions in respirable dust and silica, we've also decreased confined space entries by approximately 92%.
Reflecting on the success of this transformative project, our achievements are not solely ours but a testament to the collaborative spirit of our dedicated team. These enhancements have not only elevated our operational capacities but have also set new industry standards for environmental and safety practices.
Bingham & Taylor remains dedicated to advancing the boundaries of what is possible in the manufacturing of underground utility solutions, continuing a legacy that began in 1849. This award from the AFS and the results of our ambitious project affirm our commitment to excellence and innovation, ensuring we remain at the forefront of our industry for years to come.