Training & Development Courses Available (+500 pages in total)

       Programs include:

  • Technical (see example below)
  • Management (see example below)
  • Assessing die casting suppliers from management, technical, and processing perspective. 
  • Optimsing die casting tool life
  • etc.


        Technical/Management 4 Day Training Course




          Course Instructor

        John A. Lyons

        BE (University College Dublin)

        Course Overview


        The objective of the course is to increase the competitive advantage of those that attend by providing a detailed understanding of the die casting process and the management tools necessary to produce competitively in a global market.

        The program will be broken down into three phases.

        Initially participants will be given the theory behind the various disciplines required to produce a high quality pressure die casting.

        During phase two we will take an in depth look at each stage of the die casting process with discussion on the importance of controlling and measuring all the key parameters in order to produce a die casting of consistent quality effectively.

        The third part of the course will focus on achieving a cost effective die casting operation, this includes:

        1) Setting measurable objectives for each employee based on company’s business strategy

        2) Establishing a systematic approach to training

        3) Regular reviews of all waste (scrap, rework, etc,)

        4) Applying Lean manufacturing and error proofing to a die casting operation

        5) Utilising SPC

        A detailed discussion will take place throughout the course with reference to real life examples. Participants are encouraged to bring their problems (whether technical or management) to the course in order that options for improvement can be put forward.

        Learning will be reinforced with over 30 assignments to be completed by those that attend.





        One of the biggest costs in a die casting company is the costs to produce quality.

        1. A detailed understanding of the die casting process in its entirety. Allowing employees to have more meaningful discussions when problems arise and ultimately making better decisions resulting in improved operational performance with greater job satisfaction.

        2. Reduction in costs and improved customer performance through reduced waste from using modern manufacturing techniques.

        3. A more committed and motivated staff as a result of been given measurable objectives, and more involvement in the day to day operation along with the necessary development in order to achieve those objectives.



        Course Content


        1. Theory behind metal flow and solidification in the tool.

        Learn the theories for the different stages of injection in order that molten metal is injected effectively into the tool.

        Learn the key elements required to achieve a structurally sound casting and to avoid excessive shrinkage during the solidification phase.

        2. Understanding and Optimising the injection system on the die casting machine.

        Learn in detail how the injection end of the machine works and how to optimise the injection settings in order to have a more flexible process with less scrap/rework.

        3.Theory behind plunger size, runner/gate design, overflow/venting and die casting machine size

        Ensure your process costs are competitive by being able to predict and calculate at the design stage the time required to fill the casting cavity in order to achieve a good surface finish and the pressure required in the cavity to ensure the casting maintains its integrity.

        Minimise porosity by having a good gating system and by choosing an effective location for the overflows and vents.

        Learn how to calculate the correct die casting machine size for any particular job in order to minimise the die casting machine costs for any particular quotation.

        4. Review of each stage of the die casting process and the importance of controlling it.

        Reduce operational costs by optimising and controlling each element of the die casting process in order to have a robust process that can withstand modest change without having a detrimental affect on casting quality.

        Learn the benefits and limits of vacuum die casting.

        5. Setting Objectives based on business strategy

        Learn how through setting measurable objectives for every employee company performance and culture can be greatly improved. A very powerful tool!

        Real life examples to be discussed.

        6. Training System.

        Learn how a structured approach to training and development of staff will result in less waste, increased utilisation of equipment/resources, and improved customer performance.

        Learn how operators can be totally responsible for the quality they produce by providing them with the appropriate knowledge and tools.

        Real life examples to be discussed.

        7. Plant Key Metrics

        Learn how through regularly review waste (scrap/rework/out put/customer complaints/etc.) operational costs can be greatly reduced in a relatively short period of time.

        Real life examples to be discussed.

        8. Lean Manufacturing

        Learn how to reduce costs (people/space/WIP/etc.) and improve quality through lean manufacturing.

        Real life examples to be discussed.

        9. SPC

        Learn how to reduce costs and improve customer quality through error proofing.

        Real life examples to be discussed.

        10. Error Proofing

        Learn how by reducing process variation you can reduce costs and improve customer quality through SPC.

        Real life examples to be discussed.






        Course Subjects




        1. Metal Flow & Solidification
        2. Die Casting Machine Injection System
        3. Design of Gates/Runner/Venting System for Die Cast Tools


        Foundry Process

        1. Die Casting Machine
        2. Die Casting Tool (lock out/thermal/etc.)
        3. Pouring Sleeve
        4. Metal
        5. Ladling
        6. Casting Extraction
        7. Tool Temperature
        8. Tool Lubrication
        9. Vacuum
        10. Casting Defects
        11. Cycle Time
        12. Process Control


        Effective Management

        1. Setting Measureable Objectives
        2. Systematic Training & Development (Annual/Daily)
        3. Plant Key Metrics
        4. Lean Manufacturing
        5. Error Proofing
        6. SPC