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<td colspan="4" height="59"> <img src="images/rolls-royce.jpg" alt="Rolls Royce" width="170" height="58"><br>
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<h1><span class="write"><br>
<b>Rolls Royce</b></span></h1>
<p><span class="write"><b>Client </b><br>
Rolls Royce’s Ansty factory makes the turbine blades
for most of Rolls Royce’s acclaimed turbine jet engines.</span></p>
<p><span class="write"><b>Problem </b><br>
One particular machining process required the use of a large
number of machine tools called broaches to form the barbed “Christmas
Tree” end to each turbine blade. These broaches
had several conflicting attributes:</span></p>
<ul>
<li><span class="write">They were very expensive,
so minimising stock levels was essential.</span></li>
<li><span class="write">They had
a long lead time between order placement and receipt.</span></li>
<li><span class="write">They
had a limited life, which could be extended through
a limited number of regrinds.</span></li>
<li><span class="write">Sometimes a broach would
be destroyed. Without a spare in stock this could delay
production.</span></li>
<li><span class="write">Some broaches were part of a set,
and shouldn’t
be used individually, except in an emergency.</span></li>
</ul>
<p><span class="write">Trying to satisfy all these requirements
manually was proving very hard, and Rolls Royce asked us
to devise some software to make managing their broach stock
easier.</span></p>
<p><span class="write"><b>Solution </b><br>
We implemented a Delphi application to
manage broach stock levels, remaining regrind lives,
and replacement ordering. The application has the following
key features:</span></p>
<ul>
<li><span class="write">The value of the broach stock could
be calculated at any time.</span></li>
<li><span class="write">The availability of broaches
for a particular turbine disk could be ascertained
immediately.</span></li>
<li><span class="write">It became very easy to manage regrind
lives, and order more broaches as soon as minimum levels
were
reached.</span></li>
<li><span class="write">Overdue broaches orders could be
monitored, and the suppliers chased before the situation
became
critical.</span></li>
<li><span class="write">It became very much easier to manage
sets of broaches.</span></li>
<li><span class="write">The program is extremely reliable,
with practically zero bugs or failures, over several
years
of use.<br>
</span></li>
</ul> <p><span class="write"><b>Result </b><br>
Rolls Royce’s Ansty factory was able to reduce broach
stock levels by 30% while also reducing hold-ups caused by
the
non-availability of a required tool. The savings in stock
alone paid for the software within 6 months. An unexpected
benefit of the program was simplified staff training requirements,
with the software helping engineers comply with the strict
rules for broach usage.</span></p>
<p><img src="images/rolls-royce.gif" alt="Rolls Royce Jet Engine" width="380" height="230"><br>
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