CCAM Unveils New research and Product Development Facility During Grand Opening.

RICHMOND, VIRGINIA, March 25, 2013 – The Commonwealth Center for Advanced Manufacturing (CCAM) near Richmond, Va., today unveiled its new 62,000 square foot research facility during a grand opening event.

“The new CCAM manufacturing research center represents the expertise and passion of our industry members and university partners,” said Dr. Mike Beffel, CCAM Interim President and Executive Director.  “With the goal of bridging the gap between leading edge research and product development, CCAM is at the forefront of new manufacturing processes.”

CCAM is a public–private collaborative research center that undertakes research critical to the surface technology and advanced manufacturing industries.

The Prince George County, Va., facility was completed in late 2012 and features computational and engineering research labs, high bay production space for commercial scale equipment, and tools required for research in surface engineering and manufacturing systems.

Virginia Governor Bob McDonnell, who has helped further CCAM’s research and manufacturing goals, said, “Today’s opening of the CCAM research facility marks a pivotal moment for America’s global competitiveness.   Companies that take the important step to join the CCAM research center in the Commonwealth of Virginia become partners of a one-of-a-kind asset in the U.S.—one that drives competitive advantage in the rapidly-transforming advanced manufacturing segment of our nation’s economy.  The innovations produced at CCAM are cutting-edge, and the new facility will further Virginia as a hub for advanced manufacturing technology and high-skill jobs in the 21^st century.”

Research is currently under way in the areas of surface engineering and new manufacturing systems.  Approximately 50 student interns from Virginia’s participating universities – Virginia State University, the University of Virginia and Virginia Tech – will work alongside industry experts in several research areas at the new facility and in labs around the state.

CCAM industry members include Canon Virginia Inc., Chromalloy, Newport News Shipbuilding, Rolls-Royce, Sandvik, Siemens, Sulzer Metco, Aerojet, Hermle Machine Company, Mitutoyo, TurboCombustor Technology Inc., Buehler, Cool Clean Technologies, GF AgieCharmilles, and Blaser Swisslube. University members include Virginia State University, the University of Virginia and Virginia Tech.

The CCAM facility is located adjacent to the 1,000-acre campus of the Rolls-Royce engine component manufacturing facilities, Rolls-Royce Crosspointe.

About the Commonwealth Center for Advanced Manufacturing

CCAM is a research-based collaboration between the University of Virginia, Virginia Tech, Virginia State University and manufacturing companies worldwide. Manufacturers join CCAM as members and guide research leveraging both university faculty and CCAM scientists in two focus areas: surface engineering and manufacturing systems. CCAM recently completed a 60,000 square-foot, state-of-the-art research facility in Prince George County, Va., adjacent to Rolls-Royce’s jet engine components plant. CCAM took occupancy of the research center on September 11, 2012. For more information, visit www.ccam-va.com.

Chromalloy Sponsors Industrial Casting Seminar for Tomorrow’s Engineers.

We are pleased to announce an industrial casting seminar for Virginia State University engineering students, as part of the company’s affiliation with the Commonwealth Center for Advanced Manufacturing (CCAM).

The October 7-9 casting seminar is being held at Chromalloy’s newest superalloy foundry in Tampa, Florida, and is designed to introduce students to the techniques associated with the latest casting manufacturing processes.

“As a CCAM Organizing Industry Member, Chromalloy is offering a hands-on and classroom learning seminar for tomorrow’s engineers at our state-of-the-art investment foundry,” said Dr. Mike Beffel, Vice President, Chromalloy Castings.  “The seminar exemplifies the CCAM partnership and cooperation between industry and academia.”

“CCAM is a transformational platform that promotes collaboration between private and educational sectors, allowing advanced manufacturing companies like Chromalloy access to cutting-edge research teams at Virginia’s top educational institutions,” said Virginia Governor Bob McDonnell.

“CCAM is a centerpiece of Virginia’s efforts to promote research and development and technology commercialization, and Chromalloy’s partnership with Virginia State University is a shining example of what the Center is designed to accomplish.  Seminars such as this one offered to VSU engineering students advance knowledge in manufacturing processes and bring innovative solutions to market more quickly,” McDonnell said.

The comprehensive seminar covers the basics of investment casting including wax injection and assembly of molds, investment, pouring, final part finishing, and proprietary processes developed by Chromalloy.

Chromalloy is an Organizing Member of CCAM, a research based public / private partnership with Virginia’s leading universities – Virginia State University, the University of Virginia and Virginia Tech.  CCAM is headquartered at a new 60,000 square foot research facility in Prince George County, Va., adjacent to the Rolls-Royce jet engine manufacturing facility near Virginia State University.

Other CCAM industry members are Rolls-Royce, Siemens, Canon Virginia Inc., Newport News Shipbuilding, Sandvik Coromant, Sulzer Metco, Aerojet and Mitutoyo Corporation.

Chromalloy is a leading supplier of technologically advanced repairs, coatings, and FAA-approved reengineered parts for turbine airfoils and other critical engine components for commercial aerospace, the military and the energy industry.  Chromalloy facilities includeoperations, annexes and sales offices in 17 countries.

Chromalloy Corporate Video

Check out Chromalloy’s newest corporate video, now live.  Click here. 

Nevada repair and casting center undertakes $4 million renovation

Chromalloy’s engine component repair, manufacturing and casting center in Carson City, Nev., is undertaking a $4 million renovation and modernization to expand capacity and enable the operation to deliver parts in record time for the industry. The project will add an additional casting furnace and other new equipment to the superalloy component foundry, as well as better utilize space in a new Lean design that will improve flow and accelerate throughput.

“We are expanding the breadth and level of services for our customers worldwide,” said Nat Love, General Manager. “The Arrowhead facility is being completely renovated as we continue delivering repairs and parts to our customers. When completed, the new foundry and manufacturing and repair areas within the factory will significantly expand capacity while allowing us to offer market-leading turnaround times.”

The renovation and expansion will result in “a vertically integrated business that provides every gas turbine engine component repair service, from advanced coatings to finished foundry castings to new manufactured parts ready for installation,” Love said.

Chromalloy’s 192,000-square-foot Arrowhead operation – one of four operations within the Nevada business enterprise – provides turbine component repairs and castings for aerospace and aeroderivative engines that power military and commercial aircraft, marine fleets and electric plants in the energy industry. Customers include major commercial air carriers, the U.S. military and utility companies.

With the installation of a new, higher-capacity foundry furnace, that will bring to a total of 13 superalloy investment casting furnaces at the facility. The operation currently services approximately 15,000 components each year – and that capacity will grow by 33 percent after the modernization is complete, Love said.

“The renovation is being driven by a modern, new Lean factory layout to ensure efficient work flow and work processes,” he added. The renovation and modernization project will be completed during the first quarter of 2013. At that time a grand opening will be held for customers.

Dallas repair center employs LEAN principles to transform operations

With the goal of overhauling and modernizing an aging turbine repair center, LEAN experts at Chromalloy’s Dallas, Texas, facility designed a new factory layout and will complete the full transformation early next month. The result will be a retooled 53,000-square-foot component repair center with increased capacity on commercial aerospace work lines.

Tim Ulles, General Manager, said, “The transformation at Dallas has been a collaborative process both internally and with our customers. We solicited input prior to the redevelopment of the factory to ensure its success. Utilizing LEAN tools, including Kaizen events, the goal was to modernize and improve the work flow, performance and quality metrics.”

Activities that occurred prior to the plant teardown included work flow and process mapping. Several plant layouts were designed and evaluated before a single layout was developed for the PW4000, V2500, PT6, RB211 and other product lines.

“The result has been very positive,” Ulles said. “The new facility layout and LEAN implementation has already measurably improved operational performance – and we expect more improvement in the future.”

The facility provides advanced repairs on components including High Pressure Compressor blades and vanes, gas generator cases and compressor stators.

Customers include turbine engine original equipment manufacturers, engine overhaul shops and major airlines.

Tilburg, Netherlands, repair center welcomes business development director

Jeffrey Kraak, a European business leader in the aerospace aftermarket industry, has joined Chromalloy as Head of Business Development at the Tilburg, Netherlands, turbine repair center. Kraak is responsible for long-term growth at the company’s European operation, which specializes in component repair and overhaul and serves the major airlines. 

He joins the company from Avio-Diepen, where he held several leadership positions including Regional Director for Sales & Business Development and Senior Product Manager. Earlier Kraak held increasingly responsible positions in marketing, contract management, purchasing and engine leasing at StandardAero in Tilburg. Prior to that, he worked for several years at Fokker Aircraft. Kraak began his career serving in the Dutch Army. 

Kraak holds a degree in mechanical and electrical engineering.

Aerospace industry veteran joins Chromalloy to lead Arizona business development

Leonard ‘Bo’ Lump, a long-time aerospace business leader, has joined Chromalloy’s Phoenix, Ariz., turbine repair center as Director of Business Development. With expertise in operations, engineering, LEAN and Six Sigma, Lump is accountable for expanding the operation’s service portfolio and growing the global customer base.

The operation specializes in auxiliary power unit (APU) and small propulsion and industrial engine repairs and coatings.

Lump brings more than 13 years of success in business development, client engagement, relationship development and sales force management. Most recently he was Business Development Manager at Barnes Aerospace, a global provider of component overhaul and repair.

Earlier he was Director of Business Development and co-founder of MSL Precision, an engineering design and manufacturing service provider. Prior to that, he worked for several years as Director of Business Development, North America, for CDI Aerospace, a provider of technical solutions to the military, aerospace and satellite industries. Earlier he held roles in business development and engineering at Embedded Systems and Electronics.

He began his career in the U.S. Navy, where he earned a Bachelor of Science degree in electrical engineering. He also holds a Bachelor of Science degree from Northern Arizona University. He is a certified Six Sigma Green Belt and LEAN Advocate.