With the support of our expert engineers, Hayward Tyler have revolutionised their manufacturing process with the redevelopment of their Luton site into a world class manufacturing, testing and assembly Centre of Excellence, developing a range of mobile workstations using components supplied by Drive Lines that have improved production and safety, and significantly reduced manufacturing costs and timescales.

Having celebrated their 200th Anniversary in 2015, Hayward Tyler is one of the oldest engineering groups operating globally – and much of its global base, particularly on the power side, is classified as critical, supercritical, ultra-supercritical or ultra-ultra-supercritical. The HT Group – which incorporates both Hayward Tyler and Peter Brotherhood operating businesses – designs, manufactures, tests and services performance-critical electric motors, pumps, turbines and compressors to meet the most demanding of applications for the global energy industry. Much of this performance critical capital equipment operates under extreme conditions, including nuclear, offshore and subsea environments.

To ensure that the company continues to be recognised as world-leaders, they concentrated their efforts on improving the efficiency of their manufacturing process, which involved a study of the overhead crane operations. This led to the conclusion that a safer, more efficient and cheaper alternative to these cranes was to transport and manufacture the motors and pumps on portable work trolleys.

The development of these portable workstations – known as Crusers®, named in honour of the late Rob Cruse, who empowered graduate Oliver Buhlinger to invent the range – focussed on increasing the mobility of products weighing up to 40 tonnes, improving workflow and safety in the workplace.

These trolleys allow for units to be moved between assembly points with ease along production flowlines, streamlining the process of manufacture, significantly reducing the need for fork lift trucks or overhead cranes, which significantly reduces the cost of manufacture as well as reducing associated risks.

Oliver explained the process: “We were looking to redevelop the production floor of over 8.000sqm, including the addition of a clean assembly and test extension area of over 2,500sqm. Being able to start from a blank canvas, we were able to examine all options. To use overhead cranes and forklift trucks would be the conventional approach for moving heavy loads. However, due to the health and safety risks, Crusers® include the elimination of forklift trucks, reducing crane utilisation by 50%, to improve safety and significantly reducing manufacturing costs. The reduced crane utilisation resulted in a cost avoidance exceeding half a million pounds.”

Oliver also spoke highly of the support we offered during the project: “Drive Lines were very helpful when it came to identifying which components to use, a significant benefit when you are in the conceptual stage. Their expertise and experience helped us to identify the appropriate parts to be used.”

The Crusers® have been created in three variations, each with on-board equipment for specific duties, enabling them to meet a range of needs throughout the Centre of Excellence – which was formally opened in 2016, and utilises four of the Multi-Crusers®, eight Rotor-Crusers® and twelve Stator-Crusers®.

Drive Lines supplied the components for creating and developing the Crusers®, including the screw jack systems, bogies and linear guides used to lift and tilt the stators, and motors while situated on the Cruser®. The working platform of the stator can be moved vertically by up to 350mm, allowing for working height to be re-positioned. Combined bearings and rails, also supplied by Drive lines, allow for variable adjustment of the wheelbase, ranging from lengths of less than a metre to that in excess of 5 metres.

When a unit is moved from one workstation to another, it is simply hooked up to an electric tug, allowing for easy manoeuvrability for the operator. Crusers® may then be stationary at one workstation for a number of hours, which made detachable tugs the most affordable solution for the centre. The optimal number of Crusers® on the factory floor was also carefully considered, determining the operational use through a factory simulation of future process and product movements – and this simulation itself won Hayward Tyler the prestigious Witness Horizon Project of the Year award.

The organisation attribute their ongoing success and longevity to their philosophy of ‘customer focus, innovation, and a relentless focus on the continuous improvement of its products, processes and people’ – which is an ethos we hold just as strongly here at Drive Lines, priding ourselves on offering the best customer support, advice and guidance through even the most innovative projects, helping ideas become realities.

See the range in action, and the official opening of the Hayward Tyler Centre of Excellence by the Duchess of Cambridge, in the video above.