Lodge Manufacturing Case Story
New technology together with superior spare parts and service enable Lodge
Manufacturing Co. to consistently achieve up to 440 molds an hour with
world class casting quality that meets the stringent “no grind” requirements
of the foundry.
Two Old Timers – DISA and Lodge Manufacturing Co.
Lodge Manufacturing Co., located on the banks of the Tennessee River is America’s oldest family-owned cookware manufacturer.
Joseph Lodge started the foundry in 1896 and today the commitment to people, quality and product innovation is the same as ever in the capable hands of the fourth generation of the Lodge family.
First DISAMATIC® in the USA
Lodge Manufacturing also had the first operational DISAMATIC® machine in the United States. “Pleased with the installation!” says Mr. Leslie Kellerman in the December 1965 Modern Castings ad published just after the DISAMATIC® was installed.
From the first DISAMATIC® in 1965 operating at 240 molds per hour, the Lodge operation grew to five DISA lines in 1987 with two 2011 MK1 and three 2013 MK1 machines. The volume of cookware produced by Lodge on the DISAMATIC’s contined to increase into the mid 90’s. When it became time to upgrade, Lodge again turned to DISA. “And the next generation of the Lodge family was just as pleased with the delivery and installation,” remarks Henry Lodge, great grandson of the founder, and current Lodge President.
Quality, speed and process management
Lodge eventually replaced their five machines with two DISA 2013 MK5-B machines, both with forced mode capable of running at close to 440 uncored molds per hour. “We make over 140 items related to cookware, and we’re making almost as many castings per hour today on two machines as we did on the five older machines. In fact, we’re already planning for the next generation of DISA machines,” says Henry. “The casting finish and the repeatability that we received from our first DISA are still there. But, in addition to the increase in speed, the biggest improvement on the newer machines is the communications interface that allows us to collect operational and preventative maintenance data. Plus the operator can scan pattern plate information into the machine to ensure consistency every time we run a job.”
At Lodge, we are committed to a “no grind” program on over 90 percent of our castings and regular visits from DISA under our maintenance contract agreement helps keep the machines in top operating condition.
Lodge Manufacturing Co. currently has a Right Hand and Left Hand 2013 MK-B, both with an 18 meter Automatic Mold Conveyor (AMC) and 10.5 meter Synchronized Belt Conveyor (SBC). Both machines have the Quick Pattern Change (QPC) option, one machine has a Core Setter (CSE), the
machine without the CSE is equipped with the forced mode option. CIM Modules 1, 4, 5 and 8 are installed on both machines.
“We run two 2013 MK5-B machines with 18 meter AMC’s on each machine. One machine was installed in 1996, the other in 2000. We have had a DISA Service Contract on both machines since they were installed. The contract is for a quarterly visit. We have found the service technicians
to be very helpful on both the machines and training of our people. I attended a two week training in Herlev, Denmark and thought it was well worth the time. I recommend this training to further anyone’s knowledge on DISAMATICS. The machines speak for themselves“, says Ronald Owen,
Maintenance Superintendent.