UK Foundry

The original factory was built in Stretford. We made everything ourselves including the wax injection machines, metal melting equipment, even the fencing.

Had a factory purpose-built in Irlam; moved from Stretford with no loss of production.

Re-designed the shop floor to maximise the efficiency of manufacturing.

A bespoke Unix production, purchasing and estimating software system was designed and implemented as there was no software available on the market at the time; it was used for 15 years before upgrading to another bespoke software system in 2005 written on MS Access.

Introduced automated wax injection.

Expanded automated wax injection.

New runner system facility installed.

Converted from alcohol (used for 20 years) to water-based ceramics due to new challenging environmental legislation.

Automated robotic shell production introduced a bar-coded manufacturing system. Manual lifting became a problem with larger moulds, so manual manipulators were installed to pick up heavy loads to comply with lifting regulations and some specific DGI requirements. This has revolutionised, improved efficiency, and increased the size of moulds.

Brought DGI into the 21st century and revolutionised casting techniques: added SolidWorks 3D CAD, Mavies CAD casting simulation, Mitutoyo coordinate measuring machine, fast prototyping, and made 3D CAD models available to the shop floor.

Significant investment to balance the capabilities in the foundry to match the downstream facility.

Integrated SolidWorks CAD software and 3D CAM software were used to cut our own tooling, which allowed us to be self-sufficient in tool manufacturing.

Introduced cellular manufacture to improve efficiency.

Re-aligned the business to the changing market conditions: introduced suppliers in China for high-volume work while keeping low and medium-volume work for manufacturing in the UK. Focussed on three main requirements: quality, service, and price, which remain fundamental to our business to date. The change was completed by 2003 with no disruption to customers.

After taking a hit from a lightning strike that nearly destroyed all DGI data, a bespoke MS Access database software was designed and specifically written for DGI for production control, estimation, and quality.

Manchester Investment Castings re-branded to Dean Group International. New marketing and business strategy encompassing other types of cast processes: precision grade investment casting, commercial grade investment casting, die casting, fabrications, sub-assemblies and more.

Shell development for non-ferrous metals. Spectrometer for the analysis of Carbon Steel, Stainless Steel, Nickel and Cobalt alloys.

Multiple fast prototype tooling developments: introduced fast tooling or soft tooling options, which have bridged a gap and won several new jobs in quick succession.

Major upgrade to Access database: Estimating, Stock and Quality Control linked into Sage software, allowing for further efficiencies. DGI won the Salford Business Award for Technology as a recognition of our technical innovation and abilities.

Significant upgrade of the investment area environmental control allowing for better shell consistency, less scrap and improved quality.

Added to the capability of our spectrometer with lines for Aluminium and copper base alloys. The factory was refurbished in preparation for the forthcoming 40th Anniversary celebrations.

Significant investments into our foundry of a new aluminium melting facility and microscopy laboratory were made.

Major investment in staff and training. A new warehouse facility for storing casting for our customers to enable rapid deliveries, a new material testing laboratory, and four apprentices, two of whom are Carol and Chris’s sons, started their careers. Due to a successful sales drive and demand for UK-manufactured products, our UK manufacturing throughput increased by 300%.

Continued investment in staff and training and implemented a new raw material store.

Completion of our new specialised Aluminium line, the name we have given to this process is ELITE. The process produces gas-tight castings suitable for aerospace, military, motor sport, and any other application that requires high-integrity parts.

After two years of planning, sourcing and implementation, our ERP computer system went live in June.

Continued sales growth is seen in the ongoing development of our ERP system, as well as in the new and improved inspection area with applied lean manufacturing principles.

The purchase and installation of our in-house wax 3D printing facility.

Dean Group International celebrates its 50th birthday!