From basement workshop to global supplier: Fishercast - a division of Fisher Gauge Limited - is...

With five plants in Canada, the USA and the UK, Fishercast is widely recognised as a leading innovator in technological development of zinc diecasting, having been rewarded with unprecedented success.

However, its origins were not so grand. In 1942 Bill Fisher, trained as a toolmaker

Joined by his brothers, Chester and Frank, Bill quickly became involved with his ex-employers at General Electric, who were producing Watt-hour meters. GE had problems assembling the meter disc to the shaft, and whilst the US enjoyed success by injecting metal to form the hub, they could not replicate the process in Canada. Bill Fisher designed and built a small hand operated casting machine, which went into production in the GE Meter Department in 1945 - and is still in operation today!

For Bill Fisher, this casting machine was just another job, and assumed no particular importance. Any job, as far as the Fisher brothers were concerned, was a good one whether it be a gauge, a machine, a tool or production machining.

FROM SMALL ACORNS...

Little consideration was given to that first commission until 1947 when two engineers from the GE meter plant in the US saw the Fisher machine in operation in Peterborough. They found it was faster than the ones in the States, and Fisher Gauge Works was contracted to build two further machines for them - one for the disc and shaft assembly and one for the suspension magnet. Bill Fisher soon realised the potential of such machines and approached several other large companies including Westinghouse, Sangamo Electric, Duncan Electric, Ferranti and Packard Electric, and they all bought machines. Within a short time all household Watt-hour meters being manufactured in the US and Canada had assemblies that had been processed through Fisher machines.

Alongside the assembly machines, demand was growing for casting machines, but this had its problems. Casting machines need infrastructure, which many of Fisher's customers were not able to support. In addition many had no interest in producing the castings themselves, so suddenly Fisher Gauge Works was not only designing and building machines, but also producing the diecast components.

Major reorganisation was needed to accommodate the expansion in business, so the first dedicated diecasting plant was opened in the Ashburnham plant in Peterborough.

As the diecasting side of the business grew, it became apparent that the main market for the precision components was the US and the opening of a local plant had to be considered. US import duties for Canadian goods ranged from 8% to 65% on components for consumer products. Added impetus was given by the heavy taxation on tools produced in Canada for domestic use, yet if they were exported they were tax free, making a US diecasting operation an even more attractive proposition. Fisher's first US plant was opened in Watertown, New York, in 1964.

Both the injected metal assembly business and the diecasting business grew steadily and a second Canadian operation, the Otonabee plant, was opened in 1974. All the Canadian diecasting operations were moved to this site leaving Ashburnham dedicated to tool design and manufacture, and machine building. Further expansion followed with the opening in 1983 of a third Peterborough site - the Trent plant. This is the current headquarters for the Fishertech division which designs and builds the specialised diecasting systems used in production, assembly and fixturing operations.

The Canadian and US operations are supported by a network of representatives throughout North America, which, says the company, gives customers, an unprecedented level of service and support at a local level in addition to

direct access to Fishercast's team of design and application engineers.

GROWING DEMAND FROM EUROPE

With increasing demand to supply European markets, a European plant became a necessity and in 1993 production started at a new purpose built site at Welshpool, Wales.

At the forefront of Fishercast's European growth, the Welshpool plant is in operation three shifts a day producing millions of precision components a year for the automotive, industrial control, appliance, electronic component, power tool, computer, hardware and telecommunications industries. Customers include some of the most highly respected blue chip OEMs in the world, for whom quality and close tolerances is key.

The Welshpool plant has shown strong growth since its official opening in May 1994 and plans are in place for the next phase of its expansion to further service its European markets.

So why is Fishercast so different to other zinc diecasters? The company says that a consensus of opinion indicates that the quality of its unique flash free casting process and advanced technological developments coupled with its customer service and flexible approach have been integral to its success.

The company prides itself in its ability to produce flash free, net shape castings which it says is unique in the zinc diecasting industry - so that no secondary procedures are necessary. This is possible because of the precision of its tooling, which closes around the cavity forming a tight seal. Consequently, the Fishercast process consistently meets the exacting technical specifications of its customers, and is infinitely repeatable.

In recognition of its high quality standards, all Fishercast plants are registered to BS ISO EN 9002 and QS-9000 standards. The Welshpool plant was the first precision zinc diecaster in Europe to win the QS-9000 accolade, the quality standard by which suppliers to the automotive industry are being judged and accreditation is becoming increasingly important in the purchasing decision.

Automotive components account for a large percentage of sales, and a wide range of precision components for windscreen wipers, steering systems, locks, seat systems, and mirrors are produced in the Watertown, Otonabee and Welshpool plants for car manufacturers including Daimler-Chrysler, General Motors, BMW, Saab, Volvo, Rover, Honda, Ford and Jaguar.

PIONEERING NEW ALLOYS

Working closely with General Motors Corporation, Fishercast helped pioneer the use of ACuZinc[R] in the hot chamber process. ACuZinc is widely used in the US and was introduced into Europe in late 1996. The alloy's improved surface hardness, lubricity and wear resistance has specific advantages in the production of small components. Fishercast is one of the few companies in Europe that is sufficiently experienced to offer customers ACuZinc as a casting alloy option.

Fishercast's diecasting operations offer a wide range of alloys including ZAMAK 2, 3, 5 and 7; ZA-8 and the speciality alloy ACuZinc-5.

The company has made a significant impact on the manufacture of coupling nuts with its ability to diecast internal threads. The development of this technology was in conjunction with General Motors. It has not been an easy task but the advantages over traditional machining for certain applications were so clear that the company was determined to integrate this process into its capabilities. For customers who have a requirement for coupling nuts, diecast internal threads eliminate secondary tapping operations, resulting in no metal deformation or swarf, and the exclusion of any additional processes and handling reduces costs.

Fishercast looks forward to a period of steady and sustainable growth, its expertise, particularly in the electronics, computer and telecommunications sectors, placing it in a strong position.

Bill Fisher's original commitment to excellence and innovation still permeates the company, its management and staff. He can justly feel proud of the company's rise to international prominence within the diecasting industry.

READER SERVICE NO. J105