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CCI is organized as a dynamic, service and market oriented company, geared towards providing excellent delivery, service and quality at a low cost for manufacturers who require copper and aluminum alloy products and components. CCI provides a qualified foundry with all standard machining operations, plus assembly and packaging. The following comprise the major steps involved in our process:
Before any casting is poured, the alloy is analyzed in the CCI spectrometer. The spectrometer analyzes the sample’s percentage of 13 elements and compares the analysis to the specifications of the alloy. This analysis assures the proper alloy composition and desired physical characteristics of the product.
Connector Castings utilizes both coreless induction furnaces and gas fired furnaces with sufficient capacity and flexibility to pour a wide variety of Brass and Aluminum alloys. Some of the Brass alloys we alloy and pour include Duronze, yellow and red brasses and Silicon- and Aluminum-Bronzes, while the Aluminum alloys include A356.2 and P1020.
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Connector
Castings, Inc., ("CCI"), which was incorporated under current ownership in 1987,
has operated continuously since the 1940’s. CCI practiced and perfected the craft of
casting electrical connectors, communication connectors, lighting fixture components and a
variety of other non-ferrous sand and permanent mold castings.
Highly skilled artisans, led by a master patternmaker with 30 years of
experience in our fully equipped pattern shop, can quickly translate drawings and
specifications into precise prototypes. This in-house control of pattern making means fast
conversion of drawings into tooling with uncommon precision and accuracy. We also have the
capability of modifying and repairing existing matchplates for maximum productivity and
quality. Our pattern shop also has the ability to design, make and maintain core boxes and
permanent molds.
The
heart of CCI is its foundry. Specializing in non-ferrous alloys, we have developed an
expertise in the sand casting of copper and aluminum alloys. These alloys are cast in
molds made from high productivity automatic molding machines, jolt squeeze stations or
permanent mold machines. Our foundry is organized with two separate sand systems: one for
Copper based alloys and one for Aluminum based alloys. Once produced, castings are cutoff
and shipped to our Tennessee plant for cleaning, grinding, machining, packaging and
assembly. We also make shell cores in our core room, which allow us to both produce
complex parts and to reduce drilling and machining time.
Our
machining facility is organized into highly efficient and flexible work cells. After all
castings are washed, tumbled and ground, they are delivered to one of 10 work cells where
our trained machinists can focus on a family of parts which they are specifically trained
to produce. Each cell is responsible for all aspects of the production of the parts made
in their cell: machining, assembly, quality control and packaging. In addition, each cell
is responsible for its own preventative maintenance and process control. We also have the
capability and expertise to heat treat aluminum as required.
CCI
maintains a Wide Area Network (WAN) for running our manufacturing, accounting, and
Customer Order Tracking Systems. Both foundry and machining operations are planned through
a manufacturing resource planning system that facilitates a seamless flow of material from
raw ingot through delivery to our customers’ shipping dock. Our WAN encompasses both
of our manufacturing facilities and all interaction by our employees is on a "real
time" basis.