broschyr raleigh hall - ny fabrik för norton keramiska slipskivor
DESCRIPTION
Den 25 januari invigdes en ny fabrik, Raleigh Hall, för tillverkning av Nortons premiumsortiment av keramiskt bundna slipskivor i dimensionsområdet 300-610 mm. Den nya fabriken ligger i Eccleshall i England och producerar slipskivor främst avsedda för turbintillverkning samt övrig precisionsslipning som kräver hög material avverkning.TRANSCRIPT
Shaping the
of bondedabrasives
The Raleigh Hall PlantEccleshall
FUTURE
Saint-Gobain AbrasivesDoxey RoadStaffordST16 1EA Tel: 01785 222 000 Fax: 0845 602 6211
www.saint-gobain-abrasives.com
Form# 2114
3The Raleigh Hall Plant | Eccleshall
Moving Production to Raleigh HallProduction of abrasive grinding wheels began
in Stafford over 100 years ago. Since then
change, innovation, investment, new technology
and increased levels of expertise has led to
worldwide expansion and market leadership in
the aerospace industry.
Today, the Saint-Gobain Abrasives production
plant at Raleigh Hall, Eccleshall manufactures
a range of grinding wheels under the leading
brand, Norton. The purpose built factory
produces high precision, technical innovations
for high performance grinding in the aerospace
market.
NEW RALEIGH HALL PLANT, ECCLESHALL, STAFFORDSHIRE
World Class Abrasive SolutionsSaint-Gobain offers a number of high performance bonded abrasives designed to assist in
the manufacture of the entire structure and construction of aircraft. We are committed
to using the latest technological developments to revolutionise material removal
processes for turbine part production.
Whatever the manufacturing requirements for turbine parts, from initial foundry and
forge applications, to precision machining and finishing operations, Saint-Gobain has the
right abrasive solution.
OUR PRODUCTS
World Class Abrasive SolutionsSaint-Gobain offers a number of high performance bonded abrasives designed to assist in
the manufacture of the entire structure and construction of aircraft. We are committed
to using the latest technological developments to revolutionise material removal
processes for turbine part production.
Whatever the manufacturing requirements for turbine parts, from initial foundry and
forge applications, to precision machining and finishing operations, Saint-Gobain has the
right abrasive solution.
OUR PRODUCTS
5The Raleigh Hall Plant | Eccleshall 5The Raleigh Hall Plant | Eccleshall
Norton Quantum Norton Quantum is the new generation of ceramic
grain, with an innovative bonding system specially
developed to enhance grain performance.
The revolutionary ceramic grain multiplies cutting
efficiency by controlling grain breakdown at
micrometric level, optimising sharpness (free
cutting) and toughness (life). The newly developed
bonding system optimises grain-to-bond adhesion
and improves grain retention.
Quantum wheels can be used in low, medium and
high pressure applications, on even the hardest to
grind materials such as inconel and titanium.
OUR PRODUCTS
6 Shaping The Future of Bonded Abrasives
Altos & Altos IPX The unique elongated, extra sharp ceramic grain is
combined with a highly porous and permeable open
structure, allowing coolant maximum access to the grinding
zone and providing improved chip removal and reduced
friction. This provides high metal removal rates, improved
form holding, longer wheel life and reduced dressing with
a greatly reduced risk of metallurgical damage.
Perfect for creepfeed and surface grinding on hard to
grind materials and nickel based alloys, Altos and Altos
IPX reduce cycle times by up to 50% and increase the
number of pieces ground by 3 to 4 times, the best solution
for productivity improvement and cost savings for turbine
blade grinding.
Norton Vortex Vortex features optimised 3D grain spacing for
improved chip clearance and reduced friction. This
patented grain technology increases metal removal
rates, reduces cycle times, increases wheel life and
reduces wheel dressing when creepfeed grinding.
Poros 2 Poros 2 is a vitrified bond system specifically
designed to provide high accuracy grinding of hard
or heat sensitive materials across large areas
of contact. Accurate spacing of abrasive grains
is controlled independently of porosity, enabling
the specification of the wheel to exactly meet the
grinding parameters.
7The Raleigh Hall Plant | Eccleshall
Health & SafetyAt Saint-Gobain Abrasives, health and safety is our
highest priority and bonded wheels are produced to
the most stringent quality standards to guarantee
optimum end user safety.
Saint-Gobain is an active founding member of FEPA,
(Federation of European Producers of Abrasives) and
oSa (Organisation for Safety of Abrasives), dedicated
to the promotion of safety in the use of abrasives.
We also implement the European (EN) and
International Standards (ISO) for abrasive and
grinding machines.
QUALITY, HEALTH & SAFETY
QualityThe Raleigh Hall factory is fully ISO accredited:
ISO 9001: certifies Quality Management system
is in accordance with requirements of quality
standards.
ISO 14001: certifies Environmental Management
system is in accordance with requirements of
environmental standards.
OHSAS 18001: health and safety at work
certification.
9The Raleigh Hall Plant | Eccleshall
Health and Safety Awards
In 2005 the Stafford factory received the Diamond Award for Safety, a Saint-Gobain accolade
for exceptional achievement for safety in the plant. In addition, in 2009 the site was awarded
Millionaire status – a significant achievement of a million hours without a lost time accident.
Environmental ProtectionWaste management is undertaken to optimise
recycling activities and zero pollution of air, water
and land is defined as a major objective.
Reduction of Natural Resource ConsumptionNew production processes and procedures are
regularly implemented to help minimise the amount of
waste created during the manufacturing process.
Product DevelopmentBoth Norton Altos and Vortex wheels do not require
artificial pore inducers to achieve a high level of
porosity. By choosing Altos and Vortex you help
preserve the environment and contribute to reducing
the carbon footprint.
Eccleshall BiomassWaste and energy reduction is a high priority and
the Raleigh Hall plant is part of a groundbreaking
project; ‘Eccleshall Biomass’, a response to
Government targets to reduce greenhouse gases
and utilise alternative renewable energy sources.
Using Biomass to generate electricity, the 2.6
megawatt generator located at Raleigh Hall is
fuelled by the energy crop ‘miscanthus’ and clean
wood chip. The electricity is generated using
steam turbine technology and by tapping into this
system, Saint-Gobain Abrasives is reducing carbon
emissions, saving money and helping to preserve
the environment.
Saint-Gobain Abrasives prides itself on having
an environmentally friendly approach to all its
business activities. OUR ENVIRONMENT
10 Shaping The Future of Bonded Abrasives
Throughout history, Saint-Gobain Abrasives has
employed a highly skilled production workforce, fully
trained in all stages of the manufacturing process
from mixing and pressing to firing and finishing.
Today, the workforce has an average of 22 years
knowledge and expertise in the production of
bonded grinding wheels, a valuable asset to
Saint-Gobain Abrasives and
our customers.
OUR PEOPLE
The Raleigh Hall Plant | Eccleshall 11
Mixing All orders and recipes are viewed via the system
interface then selected to ensure the highest
standard of service can be maintained. Raw
material addition sequences, material weights
and blending times are controlled to optimise
homogenisation and minimal mixing standing time
reduces product variations.
Pressing System tools used when mixing also provide a work
to list, ensuring smooth continuation of orders from
the mixer, through pressing, to the kiln. Rotary fill
and spreading, coupled with isostatic plates ensure
even density throughout each product. This provides
consistent high quality, in-balance products. ‘Pressing
to Density’ reduces product density variations and the
fully automated handling system from mould enables
the manufacture of very soft, fragile products.
MANUFACTURING EXCELLENCE
World Class ManufacturingWCM is an international programme designed to improve productivity, quality and customer satisfaction.
Raleigh Hall has utilised the latest concepts in WCM including Value Stream Mapping (VSM), to reduce end-
to-end distance travelled from start to finish of the production process. Also, by eliminating process queues,
training operators and changing shift patterns to working 24 hours a day, 7 days a week, product lead times
have been significantly reduced, a major benefit for our customers.
12 Shaping The Future of Bonded Abrasives
Firing The end to end firing cycle of the tunnel kiln takes
two and a half days, including first stage drying.
Computer control provides consistent drying and
firing. Minimal handling is required due to firing on
refractory plates. The automatic handling system
enables smooth transfer of the unfired product to
the kiln truck.
Finishing The auto machining cell provides very fast-end
production. On-time performance is assured with
system planning tools. The cell works on a one piece
flow principle, enabling work in progress (WIP) to
be kept to a minimum and orders to be processed
in minutes. Diamond cutting, coupled with tool wear
compensation provides consistent, high quality
products.
13The Raleigh Hall Plant | Eccleshall
1893 W.O. Rooper began manufacturing rubber bonded wheels at Castle Works, Stafford.
1905Rooper & Harris Ltd. purchased by Moser, West & Bateman.
1912Universal Grinding Wheel Co. Ltd. registered to sell vitrified wheels under the trademark UNI, and Universal works started at Doxey.
1921Castle Works closed and all manufacturing concentrated at Doxey.
ABRASIVES IN STAFFORD
14 Shaping The Future of Bonded Abrasives
1933First tunnel kiln introduced.
1935Universal Grinding Wheel Co. Ltd. registered as a public company. Small housing estate built for workers at Greensome Lane, Doxey.
1937Doxey Road office block was built.
1950’sThe Doxey factory was the largest of its kind in Europe, covering a 44 acre site.
1970’sUniversal is Europe’s largest manufacturer of grinding wheels, employing 1600 people in May 1977, rising to over 2000 in the next few years.
1980’s & 90’sA number of aquisitions took place including to Foseco Plc in 1980 and Burma Castrol in 1990.
1997Unicorn Abrasives was aquired by Saint-Gobain.
1997 - 2000£6million invested into the factory, renovating building infrastructure, improving lighting, heating and ventilation, and automating production processes.
2011Production at Doxey Road plant ceases.
2012Production starts at Raleigh Hall, Eccleshall.
15The Raleigh Hall Plant | Eccleshall
Shaping the
of bondedabrasives
The Raleigh Hall PlantEccleshall
FUTURE
Saint-Gobain AbrasivesDoxey RoadStaffordST16 1EA Tel: 01785 222 000 Fax: 0845 602 6211
www.saint-gobain-abrasives.com
Form# 2114