at any one time. Another aspect of their role was also to help develop the local workforce – providing them with the appropriate support, training and guidance. While Weatherford and a local company co-ordinated and arranged the machine transport and craneage, TW Ward’s team was heavily involved in the coordination and lifting of the machines on a day to day basis – for example, helping to ensure that machines were protected, loaded and transported safely. Crucially, TW Ward’s engineers methodically applied a proven and careful programme of de- commissioning, transportation and re-commissioning of each machine. In addition to re- installation, this included, where appropriate, re-tooling, laser calibration and quality checks, process trials/capability tests and quality audits. This was followed up by any necessary refresher training for operators, setters and maintenance staff. “Indeed,” adds Mr Simpson, “the support from TW Ward has continued even after the move was completed as some of our maintenance team remain in contact with the technicians in Sheffield.”
From the outset, the strategy was to create and implement a machine relocation plan that would minimise machine downtime. “Some of the smaller machines were moved three or four at a time and were back in production within a couple of days,” explains Mr Simpson. “On the other hand, the larger machines were moved and re-commissioned one at a time so that the three to four weeks they spent out of action were effectively covered by machines of similar capability.” Part of the creation of
Weatherford’s new look manufacturing site involved the re-engineering of two large Butler Elgamill machining centres. And, again, TW Ward’s experience in successfully working with such machines came to the fore by applying tried and tested re-engineering procedures that, in every case, see such machines re- engineered to CE standards. The process begins with the machine being stripped down to basic elements and modified to take advantage of up to date technology – for example, updated gearboxes to enhance spindle performance. Machine slideways are re-ground and lined and the machines are fitted with new bearings, ballscrews, upgraded lubrication systems, redesigned hydraulic systems,
new electrics, new CNC and new drives and motors, measurement systems and interlocked guarding systems. A high quality cosmetic finish with fine attention to detail provides the finishing touch. Weatherford also transferred 15 machines from its facility near Houston and a team of TW Ward engineers travelled to
the USA to de-commission four of the larger, more challenging milling machines. The remaining North American machines were de-commissioned by Weatherford’s local team and, once all these had arrived in Abu Dhabi, the Ward engineers re-commissioned them. Commenting on the project
– the largest such project undertaken by TW Ward – Simon Whitworth, managing director of the Sheffield company, states: “With the mind boggling logistics involved it’s obvious that an enormous amount of planning went into the project. But it’s extremely gratifying to report that all went well – such was the
effectiveness of Weatherford’s strategy and the high levels of collaboration, professionalism and expertise between Andy Simpson, Weatherford’s maintenance team and our engineers.”
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