Our customers are under pressure. How we’re taking the pressure off

American manufacturing is undergoing major transition. Challenges and opportunities abound. To be armed and ready, you’ve invested in the latest technology. But a broken gear tooth just shut you down. Now what do you do?

The timing is terrible. You’re under pressure to increase production for a major new customer, and a small flaw in a gear just caused a major gearbox to fail and shut down your entire line. A stoppage was definitely not in your plans. How could this happen in a plant you heavily armed with the most advanced technology?

Unbelievable as it may sound, almost anything can cause a gearbox to fail. You can do everything right, but a weak, worn out or flawed gear or any number of other issues can cause a gearbox to fail and shut you down for hours if not days or weeks.

We’ve built our business on the promise to repair industrial gearboxes — any make, any model, to equal or better quality than original — on time, on budget, with no excuses. Like other manufacturers, we’re adapting to an industry in transition.

The challenges are abundant, but so are the opportunities for those prepared to meet them.

The fact is, not everyone is prepared. To ensure that we and you, our customers, are on the winning side, we’ve made major investments throughout our operation — in our infrastructure, technology, customer service and people. Please take a look.

A new 10,000 square-foot facility expansion:

By increasing our critical floor space and manufacturing area, we’ve alleviated previous space constraints, enabled smoother operations and increased production capacity.

New cutting-edge equipment to boost efficiency and reduce production times:

Three new Mazak lathes:

QT 250 for smaller parts
QT 350 with a steady rest
Slant Turn 550 for larger parts with live tooling

Two new CNC hobbers:

S&T 350 CNC hobber
Gleason Titan 1200 CNC hobber with extended cut length

Upgraded Mazak 400 Lathe:

Equipped with new linear guides, ball screws and way covers

KNG 12P master gear profile grinding machine:

For high-precision machining of internal and external gears as well as special profiles
With stroke speeds of up to 12,000 mm/minute

These upgrades have reduced machining times by 30% on the lathes and even more on the hobbers, leading to faster turnaround times and improved delivery schedules all while maintaining the highest quality in the industry.

AI and programming innovations:

We’re actively evaluating the use of artificial intelligence to further enhance our manufacturing processes. The new Mazak lathes are equipped with advanced controls capable of generating machining programs directly from engineering drawings, which are then reviewed by our machinists. We’re also exploring cloud-based programming tools to assist our machinists in creating more efficient and accurate parts programs. These advancements promise to further reduce setup times and improve precision, ensuring we deliver high-quality products to our customers even faster.

Workforce expansion and training:

To fill the shortage of skilled gearbox technicians and CNC machinists in the face of increased production demands, we’ve focused on attracting, training and retaining talent. These efforts are paying off, with a more skilled and efficient workforce, ensuring consistent quality for our customers.

We’ve added a second shift in the Machine Shop and Clean-and-Paint areas
We’ve added 15 new manufacturing team members

Prioritizing safety:

We continue to put safety at the forefront of everything we do. Our commitment includes:

Weekly safety meetings to reinforce best practices and address concerns
OSHA 10 training completed for all new employees
OSHA 30 training completed for employees on field service trips and management
Adherence to ISN Network safety guidelines, maintaining our A rating

These initiatives ensure a safe working environment, boosting employee morale and productivity while reinforcing our reputation as a responsible partner.