Empire Die Casting Co., Inc.
Company Information Survey
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1.0 COMPANY
  COMPANY NAME EMPIRE DIE CASTING CO., INC.
STREET 635 EAST HIGHLAND ROAD
CITY MACEDONIA
STATE OH
ZIP 44056
TELEPHONE 330-467-0750
FAX 330-467-9118
 
CORPORATION
PUBLIC
PRIVATE
MINORITY OWNED
   
DO WE HAVE A UNION YES
CONTRACT EXPIRES 2013
UNION AFFILIATIONS TEAMSTERS LOCAL 416
   
MAIN PRODUCT(S) RECREATION
MEDICAL SUPPLIES
BUSINESS MACHINES
GOVERNMENT
APPLIANCES
LAWN / GARDEN
PUMPS / VALVES
2ND / 3RD TIER AUTO
ELECTRIC INSTRUMENTS
HEAVY TRUCKING
TOOLS: HAND-POWERED
MECHANICAL DEVICES
HVAC
   
ALLOYS ALUMINUM AND ZINC
 
WHAT IS OUR COMPANY'S STRATEGIC DIRECTION/MISSION?
QUALITY DRIVEN PEOPLE DEDICATED TO PRODUCING THE BEST PRODUCT THROUGH CONTINUOUS IMPROVEMENT IN COMMUNICATION, TRAINING AND SERVICE
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2.0 BUSINESS
  YRS. IN BUSINESS 60
SALES LAST YR $ 40M
SALES THIS YR $ 50M
SALES NEXT YR $ 60M
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3.0 FINANCE
  BANK REFERENCE:
NAME CITIZENS BANK
PHONE 248-324-8646
STREET 38701 SEVEN MILE ROAD
CITY LIVONIA
STATE MI
ZIP 48152
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4.0 REFERENCES
    UPON REQUEST  
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5.0 BUILDING SPACE (SQ. FT.)
  ADMINISTRATION 15,000
PRODUCTION 100,000
TOOL ROOM 25,000
WAREHOUSE 25,000
OTHER 35,000
TOTAL 200,000+
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6.0 EXECUTIVE AND KEY PERSONNEL
  CEO RICHARD P. ROGEL
PRESIDENT ROBERT A. HOPKINS
EXECUTIVE VICE PRESIDENT PAUL HEAD
FINANCIAL CONTROLLER DENVER BORTZ
ENGINEERING MARK KUBICKI
QUALITY FRANK PRIJATEL
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7.0 WORKFORCE
  (NUMBER OF EMPLOYEES)
PRODUCTION 108
QUALITY ASSURANCE 10
ENGINEERING 5
MAINTENANCE 17
TOOLMAKERS 27
OTHER 28
TOTALS 195
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8.0 ENGINEERING RESOURCES
  FORMAL ENGINEERING DEPARTMENTS
DESIGN TOOLING
MANUFACTURING SUPPORT
REPAIR / SERVICE
 
SPECIAL ENGINEERING TOOLS
MAGMA FLOW SIMULATION
 
ENGINEERING PROCEDURES
NEW PRODUCT DEVELOPMENT PROCESS GUIDELINES
DESIGN GUIDELINES
 
FILE FORMATS ACCEPTED

STEP files
.(IGES)
.DXF / .DWG
SAT
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9.0 MANUFACTURING
  MANUFACTURING CONTROLS
ASSEMBLY PROCEDURES
WORK ORDERS
INSPECTION PROCEDURES
LOT TRAVELERS / ROUTING SHEETS PROCESS
PROCESS CHARTS
CORRECTIVE ACTION
STATISTICAL PROCESS CONTROL
 
SECONDARY CAPABILITIES
MACHINING
ASSEMBLY/TESTING
SHOT BLASTING
VIBRATORY & THERMAL DEBURR
PARTS WASHING
 
SECONDARY - (OUTSOURCE)
PAINT: POWDER, WET, POLAN, E-COAT
COATING: ANODIZE, ALODINE, IMPREGNATE, DICHROMATE, HOT COAT AND CHROME
HEAT TREAT / STRESS RELIEF
POLISHING, BUFFING, SANDING
 
DO WE HAVE MODEL SHOP AND PROTOTYPE CAPABILITIES?
YES - BOTH IN-HOUSE AND OUTSOURCED
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10.0 QUALITY ASSURANCE
  HOW ARE REQUIREMENTS / SPECIFICATIONS COMMUNICATED TO OUR SUPPLIERS?
THROUGH PURCHASE ORDERS AND BLUEPRINTS
 
WHAT IS OUR WARRANTY PERIOD?
90 DAYS ON PURCHASED PRODUCT
 
HOW DO WE MEASURE QUALITY?
CUSTOMER SURVEYS, CUSTOMER COMPLAINTS, COMPANY GOALS
 
WHAT IS OUR QUALITY ACCEPTANCE RATE WITH OUR CUSTOMERS? 99%
 
DO WE HAVE A TRAINING PROGRAM FOR NEW EMPLOYEES?
YES - 12 HOUR COURSE COVERING SAFETY, JOB DUTIES AND CONTINUOUS ON THE JOB TRAINING
 
DO WE MONITOR OUR IN-PROCESS DEFECT RATE? YES
 
HOW IS OUR IN-PROCESS DEFECT RATE MEASURED? SCRAP AND RETURNS
 
HOW ARE OUR PROCESSES CONTROLLED?
DIE CASTING PROCESS IS MONITORED THROUGH SHOT SCOPE. QUALITY INSPECTION SHEETS UTILIZED BY FLOOR INSPECTORS.
 
WHAT INSPECTION CAPABILITIES DO WE HAVE?
INCOMING INSPECTION, FAI, IN PROCESS INSPECTION, FINAL INSPECTION, LAYOUT CAPABILITIES.
 
WHAT INSPECTION RECORDS ARE AVAILABLE AND HOW ARE THEY MAINTAINED?
QUALITY INSPECTION SHEETS, IN PROCESS, INCOMING INSPECTION, DOCK AUDITS, LAYOUT HARD COPY AND ELECTRONIC.
 
DO WE USE STATISTICAL SAMPLING PLANS? YES
 
HOW ARE THEY DEVELOPED? CUSTOMER-DRIVEN SAMPLING PLAN RANGES FROM C=ZERO TO AQL-3.0
 
OUR CALIBRATION/MAINTENANCE PROCESS.
GAGETRAK SOFTWARE (ALL GAUGES IN-HOUSE ARE CONTROLLED BY THIS SYSTEM)
 
HOW IS NON-CONFORMING MATERIAL CONTROLLED?
SEGREGATED AREA AND TAG SYSTEM
 
DESCRIBE THE DISTRIBUTION OF DRAWINGS PROCEDURES, SPECIFICATIONS ETC., BOTH INITIAL RELEASES AND CURRENT REVISIONS, TO AFFECTED OPERATIONAL AREAS OF OUR ORGANIZATION.
CONTROLLED BY ENGINEERING DEPARTMENT. UPON ACCEPTANCE OF DRAWINGS, THE DRAWING IS DISTRIBUTED TO ALL DEPARTMENTS THROUGH A JOB MAINTENANCE FORM
 
ARE WE ISO 9001 CERTIFIED? YES
 
ARE WE IN THE PROCESS OF UPGRADING OUR QUALITY SYSTEM? YES
 
IS AN UP-TO-DATE QUALITY MANUAL AVAILABLE? YES
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11.0 GENERAL
  DO WE HAVE A LIST OF INSPECTION/MANUFACTURING/TEST EQUIPMENT?
YES - TWO CMM OPTICAL COMPARATORS, SPECTROMETER, AND STANDARD GAUGES.
 
 
 
 
 
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