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RELIABILITY IN HEAVY HAUL

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  • 1. Middle East Rail, Riyadh, 2014 Stephen Cantwell Head of Rail BRADKEN RELIABILITY IN HEAVY HAUL
  • 2. © 2014 BRADKEN® Business Overview Company History Business Framework Global Footprint Customers Business Scope Manufacturing Capabilities Lines of business Reliability in Heavy Haul Rail Presentation Overview Analysis & Simulation Testing & Validation Continuous Improvement Innovative Design Manufacturing Processes Maintenance & Support
  • 3. © 2014 BRADKEN® Bradken is a leading manufacturer an supplier of differentiated consumable and capital products to the resources, freight rail and energy markets Global sales of AUD$1.3B (Actual FY13) Over 5,000 employees 140,000 cast tonnes per annum & 2500 rail cars Divisions of the Company include Mining Products, Mineral Processing, Rail, Industrial and Engineered Products. Bradken operates 34 manufacturing, sales and service facilities throughout Australia, New Zealand, the United States of America, Canada, China, Malaysia, South Africa, Indonesia, South America and the United Kingdom Business Overview
  • 4. © 2014 BRADKEN® History of Bradken 1922 Bradford Kendall incorporated 1949 Listed on Australian Stock Exchange 1982 Australian National Industries (ANI) acquires Bradken 1999 Smorgon Steel Group Limited (Smorgon) acquires ANI 2001 Smorgon sells Bradken Division to venture capitalists, Castle Harlan Australian Mezzanine Partners (CHAMP) 2004 Listed on Australian Stock Exchange 2005 Acquired Roche Castings Foundry, WA and opened manufacturing facility in Mackay, QLD both in AUS 2006 Acquired G.W. Brown Pty Ltd and Wundowie Foundry both in WA, AUS. Acquired Firth Rixson Castings in Sheffield and Darlaston, UK. Bradken join Castle Harlan, Inc in acquiring 20% of AmeriCast Technologies,Inc. USA 2007 Acquired Boogan Implement Company in QLD, AUS and TMS Engineering in TAS, AUS Acquired Roll Neck Rings in Sheffield, UK Purchased 75% of Cast Metal Services Pty Ltd, QLD, AUS Opened manufacturing facility in Xuzhou, China 2008 Acquired remainder of AmeriCast Technologies, Inc. USA 2009 Opened manufacturing facility in Mt Isa, QLD, AUS 2010 Purchased remainder of Cast Metal Services Pty Ltd, QLD, AUS Acquired ALMAC Machine Works Inc, AB, CAN and Materix Engineering Pty Ltd, NSW, AUS 2011 Acquired Investment Casting Queensland Pty Ltd, QLD, AUS and Wear Protection Systems Pty Ltd, WA, AUS Norcast Wear Solutions, Canada (Mont-Joli and Toronto) which included Swanmet, Malaysia (Merlimau and Singapore) and Australian and Overseas Alloys Pty Ltd, Australia (Wollongong) 2013 New Global Corporate Centre opened in Australia (Newcastle). New greenfield foundry in Xuzhou, China was opened.
  • 5. © 2014 BRADKEN® Bradken Business Framework
  • 6. © 2014 BRADKEN® Bradken Facility Overview
  • 7. © 2014 BRADKEN® Bradken Group Global Footprint Foundry Workshop Metal Recycling Sales Office CMS Foundry Supplies 59manufacturing, sales and service facilities 5,880employees
  • 8. © 2014 BRADKEN® Major Customers
  • 9. © 2014 BRADKEN® Mining Design, manufacture and supply a range of customised consumable wear parts and capital equipment for fixed & mobile plant and equipment throughout the mining industry Sales by Industry Sectors FY 2013 Engineered Products US based foundry and machining division manufactures highly engineered, large, mission critical steel castings for the construction, mining, defence, rail and transit industries Mineral Processing Design, manufacture and supply of high quality mill liners, crusher liners and engineered parts, both domestically and internationally. Rail Design, manufacture and supply freight wagons, bogies, drawgear ;maintenance services; equipment leasing; Spare parts
  • 10. © 2014 BRADKEN® Manufacturing Capabilities Bradken is Australia’s largest combined foundry and heavy engineering group and one of the leading ferrous-casting companies in the world. Bradken has a vast network of manufacturing facilities and sales and service centers throughout Australia, New Zealand, China, Canada, United States of America and the United Kingdom. This geographical diversity underpins its position as a world class, cost effective, high quality foundry and heavy engineering company. Bradken’s manufacturing facilities employ the latest technologies in product development, design, tooling manufacture, casting processes, robotics, machining and assembly. Within Bradken there is a broad wealth of technical expertise encompassing a wide range of alloys and complex fabrication in addition to operational and field experience. This positions the company as one of the world’s most cost effective and quality founders complemented by the extensive product range and capacity offering customers high security of supply now and in the long term.
  • 11. © 2014 BRADKEN® GET & Buckets Wear Plate and Block Mining Products Crawler Systems Mineral Processing
  • 12. © 2014 BRADKEN® Mill Head Segment Crawler Side Frame Machined Double Helical Gear Industrial Multi-Axis Machining Centre
  • 13. © 2014 BRADKEN® Energy Industrial Products Resources Engineered Products
  • 14. © 2014 BRADKEN® Rail Intermodal 40 Tonne Bogie Coal Wagons Iron Ore
  • 15. © 2014 BRADKEN® Analysis and Simulation • Advanced analysis and simulation technology in the design of wagons • Assessment of operational risks, and optimisation of designs to meet customer specific requirements • Fatigue assessment is conducted to ensure reliable operation throughout wagon life
  • 16. © 2014 BRADKEN® Testing & Validation • Team of testing Engineers dedicated to development of Wagons • Testing translates into superior knowledge of the operating conditions • Wagons are validated prior to entering operation • Customers can have confidence that Wagons are suited to their individual requirements
  • 17. © 2014 BRADKEN® Testing & Validation • Designs subjected to static and fatigue testing prior to release into service • Understand in-service performance to feed into further product enhancements • Application specific knowledge facilitates work with customers to develop maintenance schedules which optimise reliability
  • 18. © 2014 BRADKEN® Continuous Improvement • Close collaboration with customers and suppliers to continuously improve performance and reliability • Ensure suppliers are of the highest standard
  • 19. © 2014 BRADKEN® Drawgear Design • Over 40 years proven history • Proving ground has enabled Bradken to develop a highly reliable drawgear system for heavy haul applications • Designs optimised using failure analysis, FEA, fatigue simulation, and product testing to destruction
  • 20. © 2014 BRADKEN® Bogie Design • Worlds first 40 tonne axle load bogie • Continued development of bogie to further enhance reliability • 40 tonne axle load bogie used by BHPB and RioTinto for over 10 years in the Australia’s Pilbara region • The use of quality components ensures reliability and reduced maintenance costs
  • 21. © 2014 BRADKEN® Manufacture Processes • Castings and forgings used where best suited within the range of drawgear systems • Stringent quality requirements and destructive testing to maintain tight control over fatigue performance • Solidification Simulation, Xray, and Phased Array Ultrasonics used extensively to ensure casting consistency and integrity • Manufacturing processes ensure drawgear operates reliably in the toughest operating conditions
  • 22. © 2014 BRADKEN® • Bogie manufacturing facility has produced high quality rail castings for over 50 years • Castings required to meet detailed inspections throughout the manufacturing process to ensure industry requirements are exceeded • Manufacturing processes ensure bogie’s operate reliably in the toughest operating conditions Manufacture Processes
  • 23. © 2014 BRADKEN® Maintainability & Support • Equipment designed to allow ease of maintenance ensuring reliability in service • Detailed maintenance manuals ensure safe and efficient maintenance • Continual technical support ensures rolling stock performs to its full potential
  • 24. Thank You

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