Welcome to e-Connections, the weekly AFS email newsletter. In this July 28, 2009, edition:

OSHA to Unveil New Recordkeeping National Emphasis Program
Over the last few years, the Occupational Safety and Health Administration (OSHA) has implemented several new National and Local Emphasis programs. These programs are designed to focus safety and health enforcement efforts on particular regulatory subjects and industries. National Emphasis Programs (NEPs) currently impacting the metalcasting industry include crystalline silica, combustible dust, lead and amputations.

OSHA is in the process of finalizing a new Recordkeeping NEP designed to look into the accuracy of injury and illness recordkeeping for evidence of under-reporting. It also will:

  • include inspections for facilities with lower injury and illness rates than their industry average;
  • target a select number of companies and industries by region;
  • include reviewing medical records and safety program policies that might affect injury and illness reporting.

Several University studies have alleged that recordkeeping data is inaccurate and that some companies are chronically underreporting work-related injuries and illnesses. In addition, these studies have alleged that employees have been discouraged from reporting work-related injuries and illnesses through intimidation, harassment and disciplinary action.

In light of this announcement, companies should expect heightened enforcement activity by OSHA focused on recordkeeping. Mistakes on your OSHA 300 Recordkeeping log could lead to a serious citation. AFS will provide additional details on the new Recordkeeping NEP in August. For more information regarding NEPs, contact Stephanie Salmon, Metalcasters Alliance for Government Affairs Office, at 202/842-4864 or ssalmon@afsinc.org.

Renewable Energy Standard in the Works
A Senate committee completed the central title of a draft energy policy overhaul that includes mandates for renewable energy and greater energy efficiency. The title would require that by 2021, 15% of the nation’s electricity come from renewable sources, such as wind and solar power.

The mandate is an increase from the 3% of electricity currently generated from renewable sources, but it is lower than both the 25% sought by the Obama administration and the 20% the committee chairman initially proposed.Some senators have indicated that they will work to push the mandate up to the levels the White House wants when the bill reaches the Senate floor. In the House, a committee approved a broad energy and climate change bill by a vote of 33-25 on May 21. The bill contains a 20% standard, of which 5% could come from energy savings from greater efficiency.

For more information, contact Alicia Oman, Metalcasters Alliance for Government Affairs Office, at 202/842-4864 or aoman@afsinc.org.

Successful Leaders, Leading Firms to Speak at Executive Conference
Many challenges face our industry, making this a crucial time for us to stay ahead of the pack. What strategies are metalcasting facilities utilizing to compete in today’s global marketplace? How is your facility measuring up to safety and health excellence? What is the status of the current political landscape? All of these questions and more will be addressed at the 2009 Foundry Executive Conference, which will be held Sept. 20-22 at the Loews Coronado Bay Resort, Coronado, Calif.

Featured topics include:

  • Beyond Employee Retention–Developing an Inclusionary Culture, Tim McMillin, Fairmount Minerals
  • The Application of the Golden Rule for Life and Business, Van Richey, ACIPCO
  • Reality Becomes Perception: McWane’s Success Story and the Public Campaign Behind It, Michelle Clemon, McWane Industries
  • Achieving Safety and Health Excellence–Being in the Top Five Most Dangerous Industries is Nothing to Brag About, Ed Foulke, Fisher & Phillips

Special events include a tour of the MCAS Miramar, which is home to the 3rd Marine Aircraft Wing of the U.S. Marine Corps, known as “America’s 9-1-1 Force.” Guests will view combat-tested aircraft as part of the tour of the flight line. Active duty Marines will introduce guests to the Marine Corps aviators. To take advantage of the MCAS tour, you must register by Sept. 1.

For more information or to register for the 2009 Executive Conference, visit www.afsinc.org/events or contact AFS customer service at 800/537-4237.

Have Metalcasting Related Books On Your Library Shelf? Donate Them Today
The AFS Butch Peters Library is seeking book and journal donations. AFS is particularly interested in obtaining the following titles:

  • Transactions of the American Foundrymen’s Association, Vols. 1-29, (1896-1920);
  • AFS Cast Metals Research Journal, Vols. 1-11, (1965-1975);
  • AFS International Cast Metals Journal, Vols. 1-7, (1976-1982);

AFS also will accept materials relevant to the metalcasting industry covering a wide range of topics, including casting processes, cleaning and finishing, energy conservation, environmental control, management, melting, molding and coremaking, safety and health, sand technology and metallurgy.

For more information contact Katie Doherty, AFS Information Resource Assistant, at katie@afsinc.org or 800/537-4237 x 294.

New Rapid Prototyping Article on MetalCastingDesign.com
The following is excerpted from the article “Alternative RP Methods,” now available at www.metalcastingdesign.com. The article is part of the site’s growing library of metalcasting reference materials. To read the full article, click here.

Several prototyping processes can provide the tools needed to make a rapid casting without developing a model through stereolithography (SLA), selective laser sintering (SLS) or fused deposition modeling (FDM).

One of them is the old-fashioned way—hard work. With the right amount of personnel and equipment, patternmakers can CNC machine a metal pattern, and a prototype can be poured within two or three weeks.

But some shops have developed unique ways to produce a viable, temporary mold for short run pours in even less time.

Learn to Lead Projects at Six Sigma Green Belt Certification Course
CMI will be offering an on-demand Six Sigma Green Belt Certification course, available anytime between July 1-June 30, 2010. Students will learn:

  • identification and collection of relevant data;
  • to lead project teams through the DMAIC process improvement methodology;
  • basic statistical tools and techniques for defect elimination and process simplification;
  • chart runner statistical software to perform statistical analysis;
  • to turn data into information and information into knowledge to make process improvements;
  • support of Black Belts on Six Sigma projects.

For more information or to attend this course, contact AFS customer service at 800/537-4237, or click here to register.

Identify Copper Alloy Defects at Upcoming CMI Course
CMI will be offering a Metallurgy of Copper Base Casting Alloys course Aug. 25-27 at Mohawk College, Hamilton, Ontario, Canada. This course will cover:

  • information on bismuth and selenium in red brass alloys;
  • characteristics of copper alloys;
  • metallurgical quality control procedures for copper alloys;
  • copper alloy defects.

For more information or to attend this course, contact AFS customer service at 800/537-4237, or click here to register.

Looking for more information on six sigma green belt certification? Achieving Six Sigma Maintenance can help. AFS Special Publications has everything you need to supplement your metalcasting training. Visit the AFS E-Store today.