by Joe Romanowski
Chairman & CEO
Machinery Systems, Inc.

Even for someone who has represented Mazak for almost 30 years, it was somewhat of a surprise to be reminded that Mazak first introduced the Integrex back in 1983 with the Slant Turn ATC Mill Center.  Since then there have been a number of Integrex generations. We are now delivering Integrex IV and E-series machines.  I decided that I wanted to interview a company that was brave enough to invest in this fledgling, yet revolutionary technology back in the mid 80s — and is still using it today.

Gleason Cutting Tools Corporation, www.gleason.com, in Loves Park, IL (near Rockford) uses the earliest and the latest Integrex technology. Gleason Cutting Tools is part of Gleason Corporation, world renowned manufacturer of gear making equipment and cutting tools.  I sat down with Bob Reuter, Foreman, and Tom Eickstead, Team Leader, and was immediately swept away with their passion and enthusiasm for what they did.  Their most recent Mazak Integrex 300 IIIST, is one of 12 machines in their Shank Cell.  The Shank Cell is responsible for parts made from bar stock (high speed steel alloys). The cell part profile is custom designed, low quantity (average run size is 3.44 pieces), complex and highly engineered.  The cell operates 24 hours a day, 6 days a week with 4 people each 12 hour shift.

I believe I have witnessed the next step beyond lean at Gleason — "flexible."  They have figured out how to compete anywhere in the world.  Tom pointed out, “all of our product is manufactured in this plant, without foreign content and much of it is sold and shipped to the Asian market.”  I was also surprised to learn that they experienced no recession between 2000 and 2003.  Their business has been solid for many years.

So how have they done this?  Bob Reuter described the culture as a team oriented environment that works “long, hard hours.”  “We’re all flexible, have great social skills and are able to communicate with each other dealing with tough issues without offending each other.” How have you managed to develop a culture like this?  Bob continued, “We hire in that image.  We scrutinize every applicant to make sure they excel in the culture I just described.  All final hiring decisions are made by the team members with whom they will be working.”

“There’s another very important rule around here,” explained Bob.  “We call it the 30 second rule.  Everything needed for quick set-up and operation of any machine in the cell must be available within 30 seconds.  Our goal is to get that down to 10 seconds.”  Almost all of their parts have to be coated, heat treated and etched.  All external operations are shared with other cells and are completed within 30 seconds walking distance of their cell.  Tom also went on to explain that not too long ago the shank parts used to travel one half mile in the plant, today they travel a maximum of 200 feet.  Also, Work in Process (WIP) inventory is continually shrinking.  It is now 8 days on its way to 3 days.  In the 1980s it took an average of 8-10 weeks to process and ship, today they’re shipping in 3-4 weeks on their way to 2 weeks.  There is considerable focus on throughput, (video link) everyone is pulling together to get the part through the cell faster and faster everyday.  The four operators do everything in the cell.  They clean the floors and machines, do preventive maintenance (PM) and make sure the parts are scheduled, queued properly, set up and, of course, inspected and shipped on time.

So what’s the role of the Mazak Integrex 300 in this cell?  Tom explained, “It’s responsible for more and more operations.”  Typically it takes about 7 or 8 different machines to complete one of their complicated parts.  Tom clarified, “with the Integrex we can reduce the number of machine operations.  This, of course, positively impacts our throughput.”  Why did Gleason select the Mazak Integrex?  Tom said, “Mazatrol programming is so friendly.  I do all the programming at the machine. I have the part programmed before the part is ready to run.  We put a lot of our secondary operations in the Integrex set-up.  It’s self sufficient, easy to operate and with what we do we know it works.”

Gleason Cutting Tools is both lean and flexible.  You know there is a pull system in place because there’s very little WIP (there’s no floor clutter).  I think what struck me most was the investment value of this 12 machine cell — it must be in excess of $3 million (my guess). While many of the machines appeared idle, throughput is the fastest in their industry.

When I see companies like Gleason I know U.S. manufacturing has a great future.  I know that cheap labor countries can be beat!  The formula for beating the low labor cost countries is — vision, available resources for investment and the willingness to invest in people, systems and equipment; but most importantly labor content must be reduced.  The Gleason Shank Cell produces significant results with just 8 people — in the good ole' U.S.A.  Gleason is a great role model for lean and flexible manufacturing executing with lightening throughput.

Everything needed to run the form grinder is on this bench next to the machine.

Shank Cell, Gleason Cutting Tools, Loves Park, IL