Under time, under budget vacuum furnace repair

Posted by Tom McDevitt on Apr 21, 2016 7:00:00 AM

The Rose Corporation helped a specialty aerospace metals manufacturer  recover from a meltdown disaster in one of their vacuum induction melt furnaces.  The meltdown occurred on December 18th, management met with customer engineers on the 19th and TRC started demolition on the 20th.  Working every day around the clock, except Christmas and New Years, TRC completed the  rebuild four days ahead of schedule and by doing so made a strong impression on the customer that TRC and The Rose Corporation can get things done. 

The rebuild was well within our “sweet spot”, that is, it’s what we do best – get in, get it done, and get out.   In other words: safety, quality, costs, and delivery. 

The vacuum furnace rebuild project was a difficult job.  Demanding deadlines, safety hazards, training requirements, materials management, skills alignment and capacity planning between TRC, Rose and Mark Metals required some impressive management in order to bring the project to its successful end.  In fact, the production team’s daily 8am meeting (Gemba), a Lean tool, provided the perfect opportunity for each group within the company to shift skills and materials capacity to keep the project on schedule.  The entire process flowed seamlessly from start to finish, so much so that the customer gave TRC additional work outside the original scope of the project.  Now that’s pretty cool.

We delivered!  There were no safety problems.  That’s saying a lot given the adverse conditions in which our guys worked with air-supplied respirators, full-body harnesses and safety extraction cables impeding their every move.   Quality was high.  The customer claims they’re drawing a lower vacuum post-repair than ever achieved before the disaster.  Costs were on target and delivery came in four days ahead of schedule.  These last two areas had significant impact on the customer’s losses on the outage.  Repair costs were lower than anticipated and they were able to get back into production sooner; therefore diminishing lost revenues.

The Rose Corporation’s Industrial Furnace division manufactures for customers world-wide all types and configurations of industrial furnaces such as batch type reheat and forging, tip-up, roller hearth, bell, car-bottom, vacuum, electric arc, and many more for both atmosphere and non-atmosphere, batch and continuous applications.  The Rose Corporation has manufactured industrial furnaces under both our RoseTM  and DreverTM  furnace brands, as well as manufacturing customized furnaces to our customer-supplied design.  We also manufacture dissociative, atmosphere generating equipment. 

In additional to the manufacture of new furnace equipment, The Rose Corporation reconditions and modernizes customer’s existing equipment to maximize production capacity and reduce operating costs.  We offer a full line of furnace spare parts such as rolls, bearings, hi-temperature gaskets, mop curtains, glo-plugs, control systems, muffles, retorts, hearth tiles, refractory, electrode holder assemblies and sub-parts, water-cooled electric cables, roof cooling cables, alloy belts, burner radiation tubes, and much, much more.