Shaping the FUTURE of bonded abrasives The Raleigh Hall Plant Eccleshall
NEW RALEIGH HALL PLANT, ECCLESHALL, STAFFORDSHIRE Moving Production to Raleigh Hall Production 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. The Raleigh Hall Plant Eccleshall 3
OUR PRODUCTS World Class Abrasive Solutions Saint-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 Solutions Saint-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.
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OUR PRODUCTS 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. 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. 6 Shaping The Future of Bonded Abrasives
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. The Raleigh Hall Plant Eccleshall 7
Health and Safety Awards QUALITY, HEALTH & SAFETY Health & Safety At 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 The 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. 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. The Raleigh Hall Plant Eccleshall 9
OUR ENVIRONMENT Environmental Protection Waste 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 Consumption New production processes and procedures are regularly implemented to help minimise the amount of waste created during the manufacturing process. Product Development Both 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. 10 Shaping The Future of Bonded Abrasives Saint-Gobain Abrasives prides itself on having an environmentally friendly approach to all its business activities. Eccleshall Biomass Waste 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.
OUR PEOPLE 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. The Raleigh Hall Plant Eccleshall 11
MANUFACTURING EXCELLENCE World Class Manufacturing WCM 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 endto-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. 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. 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. The Raleigh Hall Plant Eccleshall 13
ABRASIVES IN STAFFORD 1893 W.O. Rooper began manufacturing rubber bonded wheels at Castle Works, Stafford. 1905 Rooper & Harris Ltd. purchased by Moser, West & Bateman. 1912 Universal Grinding Wheel Co. Ltd. registered to sell vitrified wheels under the trademark UNI, and Universal works started at Doxey. 1921 Castle Works closed and all manufacturing concentrated at Doxey. 14 Shaping The Future of Bonded Abrasives
1933 First tunnel kiln introduced. 1935 Universal Grinding Wheel Co. Ltd. registered as a public company. Small housing estate built for workers at Greensome Lane, Doxey. 1937 Doxey Road office block was built. 1950 s The Doxey factory was the largest of its kind in Europe, covering a 44 acre site. 1970 s Universal 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 s A number of aquisitions took place including to Foseco Plc in 1980 and Burma Castrol in 1990. 1997 Unicorn 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. 2011 Production at Doxey Road plant ceases. 2012 Production starts at Raleigh Hall, Eccleshall. The Raleigh Hall Plant Eccleshall 15
Saint-Gobain Abrasives Doxey Road Stafford ST16 1EA Tel: 01785 222 000 Fax: 0845 602 6211 www.saint-gobain-abrasives.com Form# 2114