A new kind of computer based simulation system called CastCAE models the casting process and predicts the quality of final castings. The system makes it possible to anticipate, and hence eliminate, defects in the final product at an early stage. The first CastCAE system was installed in September 1993 at the VALMET Paper Machinery Rautpohja Foundry in Finland. The foundry produces castings for diesel engines, off-road vehicles and other applications. Use of the simulations has halved production lead times and resulted in better quality. Energy has been saved as the need for finishing work and remelting was reduced.