a.w.bell – journey to aerospace - airshow... · • cad/cam c. 1990 • soon integral to tooling...
TRANSCRIPT
A.W.Bell – Journey to Aerospace
Jason BarklaDip(CompetMan), GradDip(CAD/CAM), BTech(IndDes), MMultimedDes
Business Development Manager - A.W.Bell Pty Ltd
AW Bell The Casting Specialists Home of the ABE Casting Process
Introduction
• A.W.Bell Background and Innovation
• A.W.Bell and the Need for Transformation
• The Transformational Journey Begins
• Additive Manufacturing + ABE Casting
• Leveraging the power of Innovation
• A.W.Bell Now, the Journey ContinuesAW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell’s Plant in Dandenong South, Victoria
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Background
• Founded in 1952 as pattern-maker
• Added tooling, post-machining and sandcasting - 1972
• Transformed into an investment casting foundry - 1982
• Additive Manufacturing established in 2000
• ISO9001 and ISO14001 accredited
• Automotive, medical, general castings, some defenceAW Bell The Casting Specialists Home of the ABE Casting Process
Investment Casting Process
AW Bell The Casting Specialists Home of the ABE Casting Process
Sand Casting Process
AW Bell The Casting Specialists Home of the ABE Casting Process
• Specialise in critical duty product
• Complex parts with many features and undercuts
• Enormous range of alloys ferrous and non-ferrous– Aerospace grade and other aluminiums– Super Duplex and other stainless steels– High tensile, low alloy and high alloy steels– Various bronzes– Virtually any air-melt high-performance metals
A.W.Bell and Casting
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell Product
AW Bell The Casting Specialists Home of the ABE Casting Process
Thales
AW Bell The Casting Specialists Home of the ABE Casting Process
Marand
AW Bell The Casting Specialists Home of the ABE Casting Process
Milspec Manufacturing
Nulka, ship decoy missile
Cable entry housing
Pivot plate
AW Bell The Casting Specialists Home of the ABE Casting Process
W&E Platt
AW Bell have supplied
AW Bell The Casting Specialists Home of the ABE Casting Process
• CAD/CAM c. 1990
• Soon integral to tooling manufacture
• Specialising in complex shaped dies and tools
• Sophisticated pattern manufacture for auto industry
• Feeds in to all aspects of our processes
A.W.Bell and Innovation
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell and Innovation
AW Bell The Casting Specialists Home of the ABE Casting Process
• Rapid Prototyping in 2000
• Over 1000 projects and many 1000s of parts
• Specialising in complex metal products and prototypes
• Additive Manufacturing with investment casting
• Many parts in heavy-duty end-use applications
A.W.Bell and Innovation
AW Bell The Casting Specialists Home of the ABE Casting Process
AW Bell The Casting Specialists Home of the ABE Casting Process
• Casting simulation in 2005
• Successfully implemented across 100s of projects
• Very accurate predictor if used properly
• Indentifies shrinkage and flow problems
• Perfect R&D tool for process improvement
A.W.Bell and Innovation
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell and Innovation
AW Bell The Casting Specialists Home of the ABE Casting Process
A.W.Bell and the Need for Transformation
• From 2005 declining demand for tooling and product for automotive and other commodity industries
• One of several investment casting foundries in the region
• GFC in 2007-2008 saw the business contract
• Increasing loss of products to off-shoring
• Time to embark on a transformative journey
AW Bell The Casting Specialists Home of the ABE Casting Process
The Transformational Journey Begins
• Redefining the vision
• Lean training from top to bottom
• Building and strengthening networks and reputation
• ABE casting process
• Lifting quality standards
AW Bell The Casting Specialists Home of the ABE Casting Process
• Transform A.W.Bell into a supplier of complex metal components with high mechanical properties, into the defence and aerospace sectors.
The Transformational Journey Begins -Redefining the Vision
AW Bell The Casting Specialists Home of the ABE Casting Process
• All employees were trained in lean and awarded certificates and diplomas in competitive manufacturing.
The Transformational Journey Begins -Lean training
AW Bell The Casting Specialists Home of the ABE Casting Process
• A.W.Bell is active in regional organisations and well engaged with governments
• 2011 Inducted to Victorian Manufacturing Hall of Fame• 2011 Young Enabling Technology Entrepreneur - Agnel
D’souza• 2013 Medium-sized Manufacturer of the Year• 2013 Young Engineer of the Year - Stephen Murtagh• 2014 Lifetime Achievement Award - George Hellyer• 2014 Vic Professional Engineer of the Year - Dr Roger
Lumley
The Transformational Journey Begins -Networks and Reputation
AW Bell The Casting Specialists Home of the ABE Casting Process
• Advanced investment casting process
• High strength, high quality
The Transformational Journey Begins -Aluminium Billet Equivalent (ABE) Casting Process
AW Bell The Casting Specialists Home of the ABE Casting Process
• Pursued and gained AS9100C accreditation
• Cultural shift required throughout organisation
The Transformational Journey Begins -Lifting Quality Standards
AW Bell The Casting Specialists Home of the ABE Casting Process
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New capability & capacity includes
Shell Oven Assisted Pouring Arm
Spectrometer
FPI X Ray Heat Treatment
AW Bell The Casting Specialists Home of the ABE Casting Process
• A.W.Bell has developed a world leading casting process called ABE (Aluminium Billet Equivalent)
• Developed for Aerospace application
• High strength and high density parts
• Allows sophisticated geometries that cannot be cost effectively machined from billet
Additive Manufacturing + ABE Casting Process
AW Bell The Casting Specialists Home of the ABE Casting Process
• Additive Manufacturing supports complex shapes
• Quick turnaround of patterns, perfect for R&D
• Dimensional accuracy and stability
• Removes the need for very expensive and complex CNC cut aluminium tooling
• Proof of concept for conservative sectors
Additive Manufacturing + ABE Casting Process
AW Bell The Casting Specialists Home of the ABE Casting Process
Additive Manufacturing + ABE Casting Process
AW Bell The Casting Specialists Home of the ABE Casting Process
• Complex cast component suffering failures
• R&D program as fee for service
• Project deepened the rapport and trust with customer
• Tooling ordered and FAI parts in production
• Significant amount of other work now secured
Leveraging the Power of Innovation -Defence Project
AW Bell The Casting Specialists Home of the ABE Casting Process
2015:Tier 1: 7 parts in production
4 parts in development1 X Tier 1 assembly
In Cast Iron and Aluminium
(Cast, Machined, Painted, Assembled at AWBell.)
Tier 2: 5 partsIn Aluminium Bronze and Aluminium
(Cast at AWBell, some machined)
2012: R&D program on advanced ferrous castings begun
Defence Project:ASC : Collins Class Sustainment
Source: wikipedia
AW Bell The Casting Specialists Home of the ABE Casting Process AW Bell The Casting Specialists Home of the ABE Casting Process
• Significant progress made in the last 5 years
• Accredited aerospace supplier to companies such as Raytheon, BAE Systems, Northrop Grumman
• Continuing drop-off in traditional product and markets
• Numerous foundries closed throughout the region
• Growing order base and interest from local and export customers
A.W.Bell Now, the Journey Continues
AW Bell The Casting Specialists Home of the ABE Casting Process
Thank You for your timeJason Barkla
Business Development Manager
A.W.Bell Pty Ltd
AW Bell The Casting Specialists Home of the ABE Casting Process