International Die Casting Expert

International Aluminium, Magnesium, and Zinc Die Casting Expert (Consultant)

John Lyons

A die casting consultant with over 30 years experience as an expert in the managing and technical development of a highly automated and efficient high pressure aluminium and zinc die casting company.

Success in reorganising, restructuring, cost reduction programs, producing complex die cast parts with very low levels of rejects, technical development, quality improvement programs, and outsourcing the manufacturing of products to Asia.

I lead the company technically from being a low cost producer of low complex parts to a being a very reliable high quality manufacturer of technically complicated parts (very tight tolerances, low porosity, thin walled, die casting surface free from contamination, parts with high flatness requirement, etc.).

Bachelor degree in engineering.

Die casting consultant to a large OEM that die casts Magnesium globally.

I can develop die casting programs in your facility or in your die casting supplier's facilties anywhere in the world.

Services:

I can help companies develop strategic business plans that include a comprehensive plant wide cost reduction program.

I DESIGN DEVELOP AND IMPLEMENT WORLD CLASS:

PART DESIGN & PROCESS CONTROLS:

part DFM analysis, die design and redesign to ensure capability
innovative die casting techniques, practices, and processes that can yield defect free castings
customised die casting process controls
effective in-process quality controls
lean manufacturing tools that increase Cpk process capability for high volume production quantities

PLANT EQUIPMENT: