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Pacific Steel Casting Company
Est. 1934
Facilities Management of a
Steel Casting Company
Robert Murillo
Pacific Steel Casting Company
Facilities Manager
March 8th, 2012
Carbon Steel vs Cast Iron
• Carbon content <2%
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• Steel is an alloy of iron,
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carbon, nickel, chrome,
vanadium, etc…
• Types: Low, Medium, High, •
and Ultra-High Strengths
Carbon Content >2%
Cast Iron is basically
carbon, iron, silicon.
Types: Gray, White,
Malleable, and Ductile.
Pacific Steel Casting
In a Nut Shell
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Plant 1 opened in 1934.
Plant 2 opened in 1975.
Plant 3 opened in 1982.
Each plant equipped with state of the art environmental controls.
3 Carbon filtration systems to remove VOC from process.
Facility has the ability to demand 9+ Mega Watts during steel
production.
Recycles over 2,000+ tons of scrap metal a month.
Recycles all process materials either internally or through outside
vendors.
Largest industries serviced are Oil Tool and Industrial Trucking.
Combined plant production capacity of 2000+ tons/month.
3 Production Facilities
Sand Molding Types:
• Green Sand
• Shell
• Air-Set
Overview of Steel Casting
Production Process
My Background
• Completed trade school and
became a Certified Welder.
• Graduated Butte College with
an AS Degree in Welding
Technology.
• Graduated CSUChico with a BS
in Manufacturing Technology
with a minor in Production
Operations Management.
• Worked through college as a
Fabricator/Machinist.
• Hired by Pacific Steel Casting in
2004 as a CAD operator.
• Promoted to Robotics Engineer.
• Promoted to Plant Engineer.
• Promoted to Facilities Manager.
Professional Organizations• American Welding Society (AWS)
• Society of Manufacturing
Engineers (SME)
• American Foundry Society (AFS)
• Steel Founders Society of America
(SFSA)
Western Division Chairman
Awards and Achievements• Westec College Challenge –
Grand Prize
• Technical Paper Published in
Modern Casting Magazine
‘Minimizing Power Demand on
Electric Arc Furnaces’.
Facilities Management
• Maintenance Departments
• Operating Budget
• Equipment Design and
Engineering
• Environmental Responsibility
• Capital Equipment
Installation/Project Management
• CalOSHA Compliance
• Safety/Technical Training
• City of Berkeley
• Energy Management
• Facility Security
Projects
• EAF Dust Collector
Projects
• EAF Energy Demand Reduction
Energy Director
Rheostat
Controller
Electricity
Meter
Plant 1 Furnace Controller
Furnace#1
PC
Energy Director
Rheostat
Controller
PC
Electricity
Meter
Furnace#2
Plant 2 Furnace Controller
Electricity
Meter
Energy Director
Plant 3 Furnace Controller
Furnace#3
Projects
• LN8 Shot Blast Machine
Continuous Improvement
• Lean Manufacturing Implementation
• 5S Projects
• TPM – Total Productive
Maintenance
• Preventative Maintenance
• Predictive Maintenance
• Root Cause Analysis
Quiz
• What year did PSC first open for business?
• What is PSC’s combined production capacity (tons)?
• How much power demand does this facility require?
• What does PSC call our VOC filtering equipment?
• What are the two main industries PSC services?