Learn the details of some challenging quality improvement projects in a large iron foundry. A foundry offers many challenges to a quality engineer, with large variability occurring almost everywhere you turn, such as when dealing with quality of natural sand and clay, quality of scrap iron, humidity in the cooling air, measuring temperature of molten iron, and so on. These projects make use of many tricks from a quality engineer’s tool box—from a simple histogram to a designed experiment to uncover relationships among variables, to creating a new measure of performance for a process. They show how to go from symptoms to problem analysis, from theories to data collection and analysis, to discovery and implementation of solutions. Included in the presentation are stories of people involvement in choosing solutions and making them work. Such examples are valuable in training quality engineers.