Working with OEMs is all about reducing time and cost, while maintaining quality, says Michael Cooper, executive manager at GWL Machining
Working with OEMs is all about reducing time and cost, while maintaining quality, says Michael Cooper, executive manager at GWL Machining
Complex machined castings specialist Grainger & Worrall’s commitment to industry and the engineers of the future has been recognised through a highly prestigious, international automotive sector award.
The company held off strong competition to take the Apprenticeship Programme category at the Automotive Global Awards at a gala ceremony at London’s Savoy Hotel.
Michael Cooper, Executive Manager – Machining at Grainger & Worrall, explains why the growth of electric vehicles is an opportunity, not a threat, to businesses willing to take advantage of emerging markets.
Grainger & Worrall Machining has once again shown its commitment to meeting and exceeding the stringent standards of the global automotive sector, with a substantial six-figure investment in state-of-the-art component washing technology.
Matthew Snelson, head of quality systems at Grainger & Worrall, discusses the importance of our recent IATF16949 accreditation
How advances in lightweighting are enabling automotive OEMs to design ever more efficient vehicles
The hugely successful partnership between Grainger & Worrall and Gibson Technology continued apace this weekend, with three podiums at Le Mans. Gibson GK428 engines, cast by Grainger & Worrall, were utilised by all 20 cars on the LMP2 grid.
Rebellion Racing’s historic podium finish at Le Mans this weekend has delivered even more success for the hugely successful partnership between Gibson Technology & Grainger & Worrall.
We are pleased to confirm on Friday night Grainger & Worrall came home with the nights top award for ‘Company of the Year’, a fantastic achievement and first company to win for a second time. This award is testament to the hard work of all here at GW, congratulations and thank you to all.
Diversification into electrification and body in white is enabling the in-house machining facility at Grainger and Worrall to boost turnover.
This diversification is now contributing up to £8m to the group’s overall sales figures, Initially set up to deliver complex, low-tolerance machining support to Grainger and Worrall’s own cylinder heads and engine castings, the facility has since grown to work directly with OEM customers, delivering precision machined parts for customers all over the world.
Grainger & Worrall is exhibiting at Automechanika this week (5 -7 June), at Birmingham’s NEC.
Grainger and Worrall sends it congratulations to Will Power and Chevrolet after victory in the Indianapolis 500 this week. The win was Power’s first in the sport’s biggest race, and his 34th career IndyCar victory overall.
A global authority in castings has given a two-day seminar to engineers at complex metal specialist Grainger and Worrall, as the business continues to expand and improve its offering.
Professor John Campbell visited the Shropshire-based business to reinforce the principles of the recognised Cosworth sand casting process, which he helped to develop back in 1978. Now owned by Grainger and Worrall, the process was developed over a lifetime of work in the foundry industry to develop defect-free castings with dimensional accuracy, and high structural integrity.
During the two-day event, John Campbell presented the theory behind the Cosworth process to 40 members of the engineering department, before spending the second day discussing the key principles behind the idea, reinforcing best practice.
Keith Denholm, engineering and technology Director at Grainger and Worrall, explained that the Cosworth process is as integral to the business today as it has always been.
“As Grainger and Worrall moves into electrification, body in white, and subframes, we continue to operate to the principles set out by the Cosworth process to continually to optimise and lightweight casting materials. Although the process itself may change depending on each application, the principles it is based upon remain as relevant as they have ever been.
“We were delighted that such a recognised global authority in John Campbell was happy to visit our foundry and engage with our engineering team as we continue to grow, following his initial guidelines for castings success.”
A team of young engineers at complex metal specialist Grainger and Worrall is taking the lead on a new project expected to boost tourism to the town of Bridgnorth (Shropshire).
Budding engineers have already begun prototyping a series of 20 replica locomotive statues in the shape of ‘Catch Me Who Can’ – the world’s first fare passenger engine built in Bridgnorth back in 1808 for British inventor Richard Trevithick. Each statue will be hand-painted in a kaleidoscope of colours by local artists and placed in strategic locations around the town, to create an interactive walking trail.
The project is putting Grainger and Worrall’s apprentices under real-time engineering pressures. Not only are they being asked to design and engineer the statues based on a sketch drawing, but they also need to manufacture four a week leading up to the April 1 deadline, when they will be placed around the town. The replicas, which when cast and set on a plinth stand some 1.5m high, provide several external design challenges that the apprentices must overcome.
Ella Jones, a female apprentice at Grainger and Worrall, explained: “Throughout the design stage we have had to consider lots of requirements. The volume of replicas required in a short timeframe mean they must be practical to manufacture, which is why we are utilising a hybrid of traditional casting processes, together with more innovative 3D sand printing technology. They must also be corrosion resistant and have secure fixings, plus, be novel and quirky by design. Amidst all of these, we also need to ensure they replicate the original Catch Me Who Can in the best possible way.”
Matthew Snelson, director of systems at Grainger and Worrall, and director of the neighbouring Marches Centre of Manufacturing and Technology, which hosts the apprentices, added: “This project gives our apprentices experience of working in busy engineering conditions, utilising their skills in computer aided design, simulation, prototyping, 3D printing and sand casting. These are the skills Grainger and Worrall’s 700-strong team practise every day in response to demand from leading OEMs for complex metal solutions, and puts the apprentices in good stead for long, successful careers at the company.”
Grainger & Worrall has become one of the first UK businesses to achieve an internationally recognised automotive standard, backed by vehicle manufacturers including BMW, General Motors, FCA, Volkswagen and more.
Grainger & Worrall has announced that it has successfully achieved IATF16949 accreditation, reaching the highest standards for business systems, continual improvement, risk management and defect prevention in the supply chain.
Developed by the automotive industry specifically for suppliers, IATF16949 replaces TS16949 and outlines the requirements for an effective Quality Management System (QMS). The key to this is risk assessment, driving the organisation to learn from the many inputs it experiences, such as customer feedback, internal and external audits and improvement efforts, to provide the highest quality product and service to the customer.
Matthew Snelson, head of quality systems at Grainger & Worrall, said: “After detailed, on-site audits by Lloyds Register, we are delighted to have been awarded IATF16949 Certification and ISO9001 renewal.
“Achieving this widely recognised certification is a great reflection of the hard work and dedication of the Grainger & Worrall team, which continually pulls together to achieve significant uplifts in processes and quality systems.”
Grainger & Worrall received IATF16949 / ISO9001 certification in January 2018.
How a unique partnership between two UK motorsport titans created ‘the world’s most reliable motorsport engine’.
• Gibson / GW engines took ‘world first’ podiums at Le Mans in June 2017
• Of 25 LMP2 vehicles powered by Gibson / GW engines, 21 completed the circuit (four retirements were due to non-engine related issues)
• In total, the 4.2 litre GK428 V8 engines covered a distance of 143,440.03 kms in 719.5hrs
“We are delighted to see the increasing focus on technical and engineering skills in our region. Herefordshire is one of only a handful of counties without a university, so to have an engineering facility established in the region will provide further resources for local businesses. We hope as NMITE becomes established, it will work closely with the Marches Centre of Manufacturing and Technology, of which Grainger and Worrall is a founding shareholder.
“In addition, we have a long-standing commitment to develop the skills of our people and invest in new technology and processes. This helps drive the company forward in the highly demanding and global market place in which we operate, and any further commitment to increasing the calibre of the UK’s engineers is very welcome.
“People are the biggest asset to any company. That is why it is vital that businesses come together and work in partnership to maintain a strong pipeline of talent entering the engineering sector. We’re passionate about developing the next generation of world leading engineers in the UK and the NMITE will play a significant role.”
Rounding off a year that has seen significant machinery investment and continued major OEM partnerships, Grainger & Worrall has reaffirmed its commitment to motorsport with Director James Grainger becoming Vice Chairman of the Motorsport Industry Association (MIA).
The high precision castings expert has been an MIA member for the past decade, representing the sector on such topics as skills, Brexit, and the industry’s challenge to embrace low carbon initiatives across motorsport and passenger cars. This year, Grainger & Worrall has also played a pivotal role in launching the £4 million Marches Centre of Manufacturing and Technology (MCMT), a Shropshire-centric, industry-led training centre for young engineers. The company will also be sponsoring the Teamwork category at this January’s Motorsport Industry Business Excellence Awards.
James Grainger’s appointment as Vice Chairman of the MIA enables the business to continue to work alongside its peers in motorsport, high-performance engineering and tuning, to ensure everyone is pulling in the same direction.
James commented: “This is both an exciting and important time for the global motorsport industry, with new technologies constantly supporting the development of more efficient and lighter vehicles. As Vice Chairman of the MIA, I can help Grainger & Worrall work more closely with the sector and ensure that our members continue to have an active voice in key industry developments.”
Grainger & Worrall is no stranger to new technologies in the automotive sector. It was the first business in Europe to invest in a specialist 3D sand printer to support the casting of engine components, and pioneered the use of computerised tomography to carry out health checks on its castings, ten years ago. James Grainger added that a willingness to invest in new technologies and implement them into engineering culture is going to go a long way to helping the automotive supply chain to remain competitive amid constant change.
He stated: “Motorsport and the wider automotive sector are facing an exciting time with both legislation and technology developing at a rapid rate. Grainger & Worrall operate at the heart of this, delivering continuous innovation to the market. In my new role as Vice Chairman, I am looking forward to supporting both the MIA and its members in these fast-changing times.”
Commenting on the UK Government’s announcement that the sale of new petrol and diesel cars will be banned by 2040, Edward Grainger, a director at leading automotive castings business, Grainger & Worrall (GW), gives his view:
Praise given to a “remarkable” new engineering training facility.
Grainger & Worrall (GW), played host to an evening event for Institute of Mechanical Engineers (IMechE), organised by Birmingham Young Members Panel. The evening saw the region’s brightest engineers go behind the scenes of the high-quality automotive castings company, to gain valuable insights from GW’s expert engineers.
On 29 June, 2017, Exova the Materials testing partner of GW was acquired by Element Materials Technology. Since that date, the two companies have been working together to integrate their businesses into a single organization that will be known as ‘Element’ in the future.
Effective on or around 14 March 2018 the Bridgnorth Exova locations will start to trade as Element, whilst the legal company name will not change.
Element’s newly combined business makes us the #1 testing provider in the global aerospace and oil & gas sectors, and a market leader in the U.S. transportation and automotive testing market. With 200 laboratories and over 6200 employees worldwide, GW now have access to increased capacity, capability and expertise for all of our existing and future materials testing, calibration, certification needs.
The automotive industry’s response to emissions legislation and consumer expectations has resulted in considerable changes in engine technology recent years. Light weighting and downsizing have led to smaller and more efficient engines, returning fuel economy and emissions figures that have plummeted in the past decade. Throw into the mix the use of CAD software for the design of engines and we’re truly in high-tech territory.
In the light of the chancellor’s funding announcement of £500m a year to support technical training for young people, Bridgnorth-based automotive castings specialist Grainger & Worrall is upbeat about the future. Edward Grainger, a director of the family-owned business, said: “As a significant local employer, we welcome this budget, which is a real shot in the arm for technical skills development in our region.
Faced with the chronic skills shortage, engineering firms should take control of their own futures and establish vibrant apprenticeship and training partnerships. That is the view of Edward Grainger, a director of Grainger & Worrall (GW), the global leader in high performance automotive castings.
Shropshire-based precision castings company, Grainger and Worrall (GW), is looking for the next batch of graduate engineers to kick off their career in manufacturing. This could serve as a big break for aspiring engineers; offering them the opportunity to work with world-renowned brands including Aston Martin, Bentley and even F1 teams, all of whom are customers of GW.
Grainger & Worrall (GW), the UK’s leading provider of high precision casting technologies, opens a state-of-the-art, machining facility at its site in Bridgnorth, Shropshire. The new centre now fully operational, incorporates the existing Telford facility with an additional £5 million investment, centralising the company’s machining operations.
Leading high performance casting specialist Grainger & Worrall (GW) is working in conjunction with Jaguar Land Rover (JLR) and the Advanced Propulsion Centre (APC) to develop a new type of cylinder block that uses plasma coatings to reduce the weight and size of engines.
Aston Martin has confirmed Grainger & Worrall (GW) as its preferred engine castings partner for the new DB11. At the heart of this iconic sports car is the new 5.2 litre twin turbocharged V12. This engine sets even higher performance standards for the latest DB iteration, the cleanest, most fuel efficient, powerful and fastest accelerating model in Aston Martin’s history.
Grainger & Worrall (GW), the UK’s leading provider of high-precision casting technologies, has completed the purchase of a castings facility in Worcester.
We are delighted to be featured in The Engineer Magazine July 2016
As part of an initiative to further expand its small series automotive machining capabilities, the world’s leading total casting solutions provider, Grainger & Worrall (GW), has installed a £1.5m turnkey Flexible Manufacturing System (FMS).
10 May 2016
As suppliers aim to meet quality and reliability benchmarks, AMS speaks to a casting company that regards computer tomography as a game-changer
Global testing and certification group Exova has agreed a new deal with specialist castings provider Grainger & Worrall to deliver a bespoke in-house testing capability.
[New Richmond, Bridgnorth and Stockholm, 17 December 2015] – Engineered Propulsion Systems (EPS) has uniquely leveraged the strength and stiffness of Compacted Graphite Iron (CGI), together with a ‘flat V’ engine design, to establish a new benchmark for general aviation applications. Based on a CGI cylinder block, the 4.3 litre, eight-cylinder design results in a compact, low profile engine package that provides ease of installation, durability and low aerodynamic drag. The use of CGI enabled EPS to engineer a clean sheet Aviation Diesel engine that is setting new standards in weight, size, reliability, and most importantly, fuel consumption. Initial testing of the pre-production engine has demonstrated specific power of 105 horsepower per litre (77 kW/l), resulting in an output of 450 horsepower (332 kW). The installed wet weight of the 450 horsepower diesel engine package is within 45 pounds (20 kg) of alternative 350 horsepower (257 kW) air-cooled turbocharged engines currently used in aero applications.
Now that the dust has settled on Chinese leader Xi Jinping’s visit to the UK, it’s time to assess the true value of Britain’s relationship with the world’s second largest economy. Despite the widespread critique of the UK treatment of the Chinese delegation last month, that’s not reason enough to discount China as a hugely valuable trading partner.
Grainger & Worrall provides prototype, race and automotive casting solutions in aluminium, iron and stainless steel to a global market.
News Source : Shropshire Star Newspaper Cover Page (1) _ 27th June 2015