Sulzer Metco

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The Secret of Staying Ahead
Sulzer Eldim
High-Tech Development and Manufacturing for
Aero and Industrial Gas Turbine Components
Sulzer Metco
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Courtesy of MTU
Successful Long-Term OEM Relationships
Forward-thinking OEMs develop strong partnerships
with trusted suppliers to achieve the competitive
advantage critical to their success. Sulzer Eldim, a
Sulzer Metco Company, is a preferred partner for all
major OEMs involved in the design, development and
manufacture of aerospace and industrial gas turbines.
We take pride in establishing high quality, long-term
relationships that deliver continuous improvement
and add value for our customers. As a leading high-
tech manufacturer of gas turbine components, Sulzer
Eldim ofers true innovation, technical expertise and
state-of-the-art facilities to take projects from concept
through successful production.
Ever since it was established in 1970, Sulzer Eldims
business has been customer centered. We take a
proactive approach with our involvement at the earli-
est phases of development to improve the manufac-
turability of critical engine components.
Our experience allows us to meet the challenging
goals of our OEM clients and often exceed their
expectations. Using our production and engineer-
ing know-how, we continuously improve our internal
processes, thereby beneting our customers with
reduced manufacturing costs and improved part-
to-part repeatability. Combined with our ability to
produce the required volumes and quality, Sulzer
Eldim is a trusted partner committed to the success
of our clients.
Sulzer Metco
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Over the course of 40 years, Sulzer Eldim has
selectively added in-house production processes
to produce a focused range of specialized compo-
nents. This comprehensive portfolio of manufactur-
ing processes allows Sulzer Eldim to develop and
manufacture critical engine components as a one
stop shop. Thus, we can easily adopt manufacturing
processes to meet changing customer requirements,
including challenges that call for modication to the
original component design The various components
are processed in a state-of-the-art, cellular manu-
facturing environment with a focus on customer
requirements and supported by lean manufacturing
methods. This has translated itself into our com-
pany achieving high on-time delivery and quality
performance.
Unique Scope of In-House Manufacturing Capabilities
Sulzer Metco
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Aero engine labyrinth seals, bafes, inserts and
compressor vane assemblies form part of the gas
turbine and are critical to the overall performance
of the engine. Sulzer Eldim takes pride in our ability
to deliver engine-ready parts as a one stop shop
supplier. When customer requirements include value-
added processes sourced outside, Sulzer Eldim is
fully able to manage the total value chain, allowing
us to respond quickly to changes in design require-
ments or production schedules.
We strive to provide our customers with competitive
oferings that deliver both value and exceptional busi-
ness benets with innovative solutions that help our
customers improve engine performance, increase
reliability, and ensure safe operation of their engines.
Compressor Stator Vane Assemblies
Sulzer Eldim specializes in HP compressor vane
assemblies fabricated from high quality stainless
steel or superalloy materials. Compressor stator
vanes are often complex assemblies which are deliv-
ered in two halves or as vane segments. Individual
complex 3D vanes, unshrouded and solid, can also
be manufactured in house to close tolerances by
means of a cold-forming and rolling process.
Seals for Industrial Gas Turbines & Aero Engines
Most seals made at Sulzer Eldim are used in the hot
section of the engine, in the HPT and LPT turbine.
We also manufacture HPC compressor seals. These
seals can be outer air seals, interstage seals or
have another sealing function in the engine. We can
supply these seals as an individual segment, as a
complete ring or are part of a more complex compo-
nent (assembly).
Seals can be made from ash butt welded, forged
or cast rings or they are made as a fabrication from
sheet metal details. We can also produce seals using
thin wall cast segments a manufacturing meth-
odology that is growing in popularity. The seals are
made from corrosion and high temperature resistant
superalloys.
Competitive Oferings for the Aero Engine Market
Sulzer Metco
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Sulzer Eldim is a world-leading service provider
for the industrial gas turbine market dedicated to
the advancement of our customers competitive
oferings.
Our in-depth technical knowledge enables us to
develop exclusive technologies such as electrochem-
ical drilling of cooling holes of various diameters and
lengths in complex airfoil structures. This distinctive
processing technique makes it possible for airfoils
to operate in hazardous environments for extended
time periods.
At Sulzer Eldim we understand that every OEM is
challenged to improve gas turbine efciencies, for
which Sulzer Eldim has successfully developed
capabilities to drill ever more complex contoured
holes, thereby improving cooling efciency and air-
ow for critical engine parts.
By gaining an intimate understanding of each cus-
tomers requirements and assessing their design
goals, we are capable of providing our custom-
ers with short cycle times for production batches,
whether for short runs or high volumes. Sulzer
Eldims internal process improvement initiatives con-
tinuously focus on reducing cost-of-quality, thereby
enhancing our customers competitive advantage.
Airfoil Processing
Sulzer Eldim excels at applying features on gas
turbine airfoils that include lm cooling holes, internal
cooling holes, seal slots, tip cavities, root notches, tip
closures and coatings. Sulzer Eldim can also deliver
engine ready parts as a one stop shop supplier
with responsibilities for casting, conventional machin-
ing, non-conventional machining and coating.
Bafes & Vane Inserts
Sulzer Eldim is active in the design, development and
production of bafes, vane inserts, core plugs and
related sheet metal products for hot section turbine
applications.
Leading Hole Drilling Technologies for the Industrial Gas Turbine Market
Sulzer Metco
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Sulzer
LEAN
Action
Oriented
Value Creation
Continuous
Improvement
Waste
Elimination
Throughout
Our
Organization
Living Our
Core Values
Operational excellence is one of Sulzers core val-
ues and is driven via the Sulzer LEAN initiative an
action-orientated management philosophy, adopted
throughout our organization by all Sulzer employees,
with the objective of creating value for our customers
and stakeholders through the elimination of all waste
and our desire to efect continuous improvement.
With Sulzer LEAN, we orient our key company pro-
cesses towards responding faster and better to the
needs of our customers, which ultimately generates
growth. These eforts are supported by sharing LEAN
knowledge and best practices throughout Sulzer.
Product Development Engineering
Our broad expertise in production engineering
covers a wide variety of products and processes.
Often, our engineers collaborate with OEM design
engineers at the earliest phases of product develop-
ment. Our Project Managers support this concur-
rent engineering concept with communication and
coordination. We have the ability to rapidly design
and manufacture the necessary tools and xtures
to meet tight development cycles and our extensive
production engineering know-how supports subse-
quent high volume production requirements. This
expertise results in decreased time-to-market for our
customers products.
Driving Operational Excellence With Sulzer LEAN
Sulzer Metco
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Cellular Manufacturing
Sulzer Eldim has based its production organization
on the cellular manufacturing concept. As an exam-
ple, we process families of components using semi-
autonomous teams. The focus of these teams is to
operate as efciently and efectively as possible to
provide a competitive ofering. Each team is support-
ed by in-cell manufacturing engineers driving contin-
uous process improvement. In-cell key performance
indicators provide each team with continuous feed-
back on their performance. This approach allows us
to maximize the use of our internal resources.
Zero Defects
Key to the performance of Sulzer Eldims cellular
manufacturing concept is our Zero Defects policy.
This policy has been initiated to reduce our Cost of
Quality and to maintain our excellent delivery per-
formance. Our Material Review Board, consisting of
Cell Engineers, Production Team Leaders and Qual-
ity Engineers, has the objective to decrease scrap
and increase First Time Right production. The Cell
Engineer also supports our Production Operators
with root cause analysis to structurally improve our
internal processes. Furthermore, we continue to
deepen the working knowledge of our operators by
providing them with recurring process training using
experienced, in-house trainers.
Cellular Manufacturing Maximizes Efciency
Sulzer Metco
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Sulzer Eldim (NL) BV Sulzer Eldim (HU) Kft.
Spikweien 24 Hatr str. 1/c.
NL-5943 Lomm AD 4031 Debrecen
Netherlands Hungary
Telephone +31 77 473 1919 Telephone +36 52 501 272
Telefax +31 77 473 2485 Telefax +36 52 418 707
E-Mail info.senl@sulzer.com E-Mail info.sehu@sulzer.com
2010 Sulzer Metco. All Rights Reserved.