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Operators who receive on-going training are more efficient and work smarter when grinding rolls. Wallen, Inc.'s personalized classroom instructions and hands-on training are important steps toward enabling operators to improve both roll quality and grinding production.
UTILIZING MAXIMUM ROLL GRINDER CAPABILITY?:
In the past, manufacturers supplied the roll grinders and training to operate them, however, the art of roll grinding was left primarily for the roll grinder Operators to develop. They had to learn which grinding wheels and/or belts were best for each type of roll and how to use them. The trial and error took time, cost money and, in some instances, the Operators were never able to get the roll grinder to achieve full production capability. Furthermore, many mills whose Operators learned to get full production from the roll grinder have since lost that ability with the retirement of those Operators.
In some cases the Operators were not able to get full production capability because the roll grinder itself had mechanical or electrical issues that prohibited good grinding. Many of these issues have been corrected but there are still some handicapping the Operators.
Therefore, as a result of Operators having to train themselves by trial and error, experienced Operators retiring without training replacements, and roll grinders with mechanical and/or electrical issues, there are many roll grinding operations that are not achieving the maximum production capability.
Wallen, Inc.'s training takes into account the knowledge and experience of the Operators. It has proven to be a huge asset to multiple roll grinder Operators, regardless of time in grade. It provides the Operators with the knowledge required to perform their work with full confidence in their ability to provided good quality in the shortest time.
The normal practice is to have a week of training/re-training with a return trip in 3 or 4 weeks for a back-up review. During this time of tailored instruction the Operators work and learn together, establishing common practices and improving communication between each other and with their Supervisors. This by itself results in increased overall production.
LATEST & BEST TOOLS:
Grinding wheels and belts have had many improvements over the years and Operators needs to be aware of the best tools available. For example, there are grinding wheels that work good for ruffing C.I. rolls and can be used to polish the roll to 7 micron finish. This reduces grind time by eliminating the need to stop and change grinding wheels, therefore, increasing productivity.
If the roll grinder Operators are grinding with belts, it is imperative that they use the belts with the special splices. If belts are ordered with a standard splice ghost-tracking marks with show up on the roll.
Coolants are also a very important part of grinding. A poor coolant can load up the grinding tool and limit the grinding process.
The choice of wheels, belts and coolants need to be purchased is best determined by the roll grinding team. Wallen, Inc.'s training will give the Operators and Supervisors the knowledge that they need to select not only the proper tool, but also the latest and best tool for each type of roll.
ROLL GRINDER ADJUSTMENTS:
Roll grinder adjustments and roll set-up are extremely important to the roll grinding process. A good set-up and well adjusted roll grinder will eliminate grinding problems and minimize grinding time.
Wallen, Inc. adjusts the training to the customer's equipment and particular needs.
OPERATOR TRAINING SUMMARY:
Our Operator training is a blend of:
Wallen, Inc.'s roll grinder training "Lesson Plan".
Wallen, Inc. Roll Grinder Service & Parts