“It’s a big company with a small company feel,” says Chief Executive Officer, Bob Hazelton.

ABA-PGT specializes in full-service injection molding and mold making. The company produces high volumes of parts and products for the automotive, bill validation/paper handling, water management/lawn sprinkler, window and door closure, HVAC, and medical markets. Of these sectors, medical accounts for about a third of all business at present.

Most services are self-performed at a 68,000-square-foot plant in Manchester and a 14,500-square-foot operation in Vernon, Connecticut. “99 percent of the work we do right here,” says Hazelton. “We do our own heat-treat, our own design work, our own gear engineering. We’re big on gear engineering. That’s our bread and butter. We do our own tool build, molding, and prototypes.”

The company can make everything from production molds to two-shot molds, high-cavitation molds, single cavity molds, multi-cavity molds, and multi-side action molds. In addition to molding machines, the team uses CNC machining as well as the latest technologies—manual mills, lathes, grinders, electrical discharge machining (EDM) systems, and laser welders—in its mold building processes. About 60 percent of its products are shipped to international clients.

ABA-PGT describes itself as an “invisible suppler,” and by this, it means clients can count on receiving high-quality goods in a timely fashion with as few hassles as possible. Customers will not be barraged by sales pitches either. “We tend not to try to dazzle the customers with a Bruins game or a golf tournament. It’s more about the products and the projects and solving problems,” Hazelton states. “Without the customers, we’re nothing.”

The company’s history extends back to 1944, when three entrepreneurs blended their last names—Anderson, Bertsche, and Anderson—to create ABA Tool & Die. At first, the company focused on metal component machining, expanding into precision injection molding in the 1950s. During the 1960s, ABA started making precision injection molds for plastic gears and in 1969, injection molding work was spun into a separate branch called PGT (Plastics Gearing Technology).

The two separate branches were merged to form ABA-PGT Inc. in 1992. More milestones followed, with the Vernon facility opening in 1996, followed five years later by the addition of two-shot molding as a service. In 2002, the company moved into its current facility in Manchester.

The merger between the company segments also marked a new direction. ABA-PGT became an employee stock ownership plan (ESOP) corporation. Under an ESOP, stock is made available to all staff, who directly benefit from the company’s overall success. Instead of being owned by a single person or a handful of partners, ownership is spread among the workforce. ABA-PGT staff members also gain from a profit-sharing arrangement, dental and medical coverage, and a generous 401(k) plan.

“The ESOP owns the company. The employees own 100 percent of the stock of the company. As people retire, the stock gets turned back in and gets redistributed to the current employees,” says Hazelton.

The ESOP has helped cement employee loyalty, as evidenced by the fact the firm has minimal turnover. “The employees here feel like it’s their company, and they pitch in. At the end of the year, if there’s a net income, it goes to the employees one way or the other, either back into the company, the bank, or as a cash bonus payout.”

To mark its 80^th anniversary in 2024, ABA-PGT offered everybody in the company and their spouses a sea cruise, and regularly hosts summer picnics, Christmas raffles, and other special events. “The culture in the company is different than a lot of companies out there. When something is needed, these guys step up and pitch in, whether it’s extra effort or hours,” says Hazelton, adding that the company has “the greatest employees.”

Management is also happy to sacrifice if need be for the good of the business. Managers voluntarily took a five percent pay cut during the 2009-2010 recession, for example. The company has since gotten back on its feet and done a roaring business over the past few years.

ABA-PGT currently has 120 employees, most of whom work at the Manchester site, while the Vernon plant operates in lights-out fashion with molding machines kept on throughout the night without human supervision. A small crew arrives each morning to review the night’s output, make needed adjustments and perform other tasks; the company operates on a continuous work schedule.

For all its success, ABA-PGT does face its share of challenges, such as securing new workers. “We have a tough time finding employees… they’ve got to be the right ones. They have to have a full understanding of all the benefits,” says Hazelton. “It’s such a long learning curve to learn what we do here. We can’t afford to have people come in, [have us] train them, then they leave. So, we really invest in people… Because they’re the owners, you want them to succeed.”

To this end, the company prefers to promote from within and will pay 100 percent of schooling costs for staff who wish to further their education.

ABA-PGT relies heavily on repeat business and referrals, does not employ outside sales staff, and keeps promotion to a minimum. “We don’t do a lot of advertising; we don’t do a lot of marketing and sales,” Hazelton tells us, adding that good word-of-mouth is the best advertising there is.

Certainly, it helps that the company has a reputation for doing excellent work and a breadth of quality certifications. Over the years, ABA-PGT has earned ISO 9001:2015 and ISO 14001:2015 status for manufacturing precision plastic components and other products via injection molding, and ISO 13485:2016 certification for medical-related molding work. It is also ISO/TS 16949:2009 and IATF 16949:2016 certified for automotive products sold to international markets.

To maintain these certifications, ABA-PGT runs a comprehensive production inspection process that entails extensive documentation, monitoring, measuring, and verification. The company uses coordinate measuring machines, vision systems, sensors, and other software and hardware to gauge quality and stresses the importance of high standards at every step.

While plenty of other tooling and molding businesses employ their own thorough quality assurance procedures and own measurement/inspection equipment, ABA-PGT has an additional asset that helps it shine: the company’s ESOP status means there is no money-obsessed owner “that wants to squeeze every dime out of the company,” says Hazelton. Since everyone at ABA-PGT benefits from maintaining a healthy revenue stream, employees recognize the importance of consistently hitting quality benchmarks. On top of this, the company regularly buys new, top-notch equipment. Recent purchases include a five-axis machining center and a high-speed milling machine.

Going forward, ABA-PGT is intrigued by the possibilities posed by AI. The plan is to utilize artificial intelligence in various machines and procedures. “We just started to incorporate it into our development process and production. I want that AI presence in the company,” says Hazelton. “The times we’ve use it, it’s really helped out. It’s definitely a focus right now.”

While exploring AI’s potential, ABA-PGT is also “very eco-conscious,” and focuses on maintaining a clean facility, he continues. The firm recently conducted an energy audit at its facilities, adding optimized lighting among other measures.

Expansion is also on the agenda. Instead of building a new facility or adding on to existing structures, Hazelton is investigating the idea of purchasing a small molding company with experienced workers. “There are a lot of companies out there that have talented individuals: toolmakers, molders, and inspectors,” he notes.

Buying another company would enable ABA-PGT to grow without the need for a lengthy training period to bring new staff up to speed. Making such an acquisition is entirely doable, given its excellent financial position. “The company itself is debt-free. We own both facilities and the land and every piece of equipment in it. The employees are the owners,” says Hazelton.

Expansion is such a given that he frets more about the dangers of runaway growth. He aims to continue to build the company up, but not in a pell-mell fashion. “My goal right now is not to grow too fast—have controlled growth. It’s definitely going to involve AI and a lot of automation. We want to get into some assemblies and bigger programs but do it in a way where we can compete.”

ABA-PGT managers like Executive Vice President, Brian Lavoie, agree, emphasizing the human factors that have made the company such a success. “It is really about the people at the end of the day—the synergy we have all working together,” says Lavoie. “It’s really made it a totally awesome place.”

The post This Employee-Owned Business Offers Tooling, Molding, and a Positive Work Environment<p class="company">ABA-PGT</p> appeared first on Manufacturing In Focus.

The name itself stands for THK’s promise of “toughness” “high quality” and “know-how,” three pillars that stand behind the products, the people, and the processes that elevate the value the company brings to its customers across. This level of service delivery has served as the foundation of its global reputation since its founding in 1971 and continues to fuel its efforts to remain an industry leader in performance and market share.

Made-in-America quality
THK was first established in Japan with the objective of supporting the machine tool industry through the integration of its linear guides—which the company was first to invent—and anti-friction technology. These products promised less friction and improved accuracy and repeatability versus the established industry standard.

As Edward Johnson, Vice President of Sales, explains, “The linear bushing was in effect since the ’40s basically; it was an acceptable technology for light loads and those kinds of lines, but the THK-style of profile rail with the circular raceways just increased the amount of load carrying capability and the speed and accuracy at which you could operate.”

With that success, THK began its outward expansion to better service customers where they were around the world, widening its footprint and its repertoire of components and expertise.

By the early 1980s, THK had established a sales presence in the United States and over the next decade it would become a major distribution hub for the brand, which was simultaneously expanding into Europe and other markets at the time. “The philosophy of the organization has been ‘How do we produce product closer to the customer to meet the demands that are there and eliminate duties and shipping?’” Johnson shares, which is more important today than ever before as customers continue to seek opportunities to re- and near-shore in North America.

In 1997, the company recognized that the U.S. market was a stronghold, and as such, investments were made to establish a manufacturing footprint, THK Manufacturing of America, Inc. in Hebron, Ohio. This facility has grown at an impressive rate throughout the last several decades, from 99,000 square feet to 401,692 square feet, to become an important part of the company’s global footprint of 26 facilities representative of millions of square feet of manufacturing capacity worldwide.

Investing in innovation
As THK America’s manufacturing capacity grew, so too did its innovative edge. With an “inventor mentality,” the company regularly expands the performance and value of its offerings to be “first movers” in new technology.

“In ’96 we produced a new technology,” Johnson recalls. “Instead of a linear guide with a full complement set of balls and it just circulating, we developed the cage product, which expanded our business significantly. It opened opportunities for a better solution for customer needs.” The company has only continued to innovate, introducing, for instance, its ISO-Compliant Dimensions Super-Low Waving Caged Ball LM Guide (with 8-row raceways) in 2024.

The cage technology afforded higher speeds, less particle generation, smoother motion, extended lubrication intervals, and longer life, which was of particular value for sectors like semiconductor and medical applications that command tight tolerances and clean production.

This ability to innovate is possible thanks to THK’s annual commitment to its research and development and in-house testing budgets, and enables the team to produce several new products each year.

“That ability to be a leader and to develop products to be on the leading edge in 3D printing, medical robots, life sciences, semiconductor, machine tools, and the aerospace work that we’re doing—being the first entry into a lot of these sectors gives us a stronger position, particularly in a marketplace where the product has become much more commoditized,” Johnson explains. THK is thus known as much for its innovation as for the commodities it produces.

More than commodities
Certainly, the customers who rely on THK components seek out reliability and performance, but the support that backs that is what truly brings value to the market. Where time is money, unplanned shutdowns of high-volume operations can quickly amass losses, which is why THK has introduced OMNIedge, a retrofittable IoT condition monitoring solution that promotes planned and predictive maintenance to empower foresight, reduce losses, and optimize uptime. Backed by U.S.-based service and support, the value THK delivers is unrivaled in the market.

Furthermore, THK’s engineering-led sales model positions the engineering team as an extension of the sales team to ensure that a solution exists for every problem—even if that solution calls for true customization. This is made possible thanks to the depth of knowledge and experience of THK’s team, a majority of whom have been with the company for over a decade.

“When you produce a product like a miniature linear guide that’s one millimeter in width and then you go all the way up to the ones that go underneath the base of buildings for seismic capabilities that carry 100 tons of load, there aren’t too many applications you’re not going to be able to find a product for,” notes Johnson of the range of THK’s expertise.

In response, industry-leading talent is attracted to the sense of curiosity that permeates the culture at THK. From President Nobufumi Sato through the ranks, Johnson credits this call to curiosity as being a driving force in the company’s ability to innovate. He and his team continue to ask, “‘How do I make lives better? How do I make this machine function better?’ We do a lot with surgical robotics and various types of medical applications, and those sectors are all about helping people have a better life.” This approach becomes an extension of the work THK undertakes on these customers’ behalf.

Enriching lives
From the end users of its products to the team that drives value in its operations, the culture and quality mindset of THK America continue to move the needle forward. The goal is to continue to develop a stronger factory automation team that can better integrate components and solutions into customer operations to improve efficiency and output, and the team looks forward to growing further in key verticals such as machine tools, 3D printing, life sciences, aerospace, service robotics, automotive, and semiconductors in the process.

Now, the question Johnson asks is, “What more can we do to penetrate those markets and the efforts that are going on?” which includes consideration of how to better leverage the strength of its components and its deeply rooted expertise to become a component part of its customers’ operations as a manufacturing and innovation supplier.

The answer is to continue doing more of the same, which is to say, replicating the culture of curiosity and innovation that drives growth while reinforcing the ‘toughness’ ‘high quality’ and ‘know-how’ that THK’s products, people, and processes bring to the market.

The post Enriching Lives Through Curiosity and Innovation<p class="company">THK America</p> appeared first on Manufacturing In Focus.

In the world of original equipment manufacturing (OEM), effectively managing fastening complexities and assembly variability is crucial to preventing costly bottlenecks while safeguarding return on investment (ROI). Bossard Americas addresses these challenges and more.

With a selection of over 1 million rivets, nuts, bolts, and other fasteners, Bossard Americas is a trusted fastening hardware distributor providing innovative, value-added services that extend far beyond basic fastening. With nearly two centuries in the industry, this formidable thought leader delivers layers of value that make its assembly solutions portfolio exceptionally robust.

Ultimately, Bossard Americas restores the definition of ROI to its rightful place. As every OEM knows, resolving bottlenecks leads to long-term project success and improved bottom lines. To this end, the company provides turnkey engineering integration, fastener fabrication, smart factory assembly, testing, and AI-assisted inventory management through smart factory logistics. It is trusted by some of the world’s best-known OEMs and pre- and sub-assembly suppliers of all sizes to optimize their assembly strategies with expert engineering and forward-thinking technology.

Established in 1831 in Zug, Switzerland by founder Franz Kaspar Bossard-Kolin and his family, the once-small hardware store has grown into a multinational company with impressive reach. While the parent company remains headquartered in Zug, Bossard Americas is based in Cedar Falls, Iowa. A collective team of almost 3,000 employees serves customers in 35 countries around the world.

The myriad assembly challenges OEMs can face make working with Bossard an obvious choice: high-speed fabrication comes with unplanned assembly risks; lightweight materials present fastening difficulties; torque variability causes rework; joint design failures demand downtime; inventory deficits slow down fabrication, and, perhaps most critically, workforce issues lead to process inconsistencies. As a powerful industry partner that works to address all these challenges, staying at the cutting edge is essential, so Bossard’s service technicians provide onsite support during onboarding, ensuring processes are set up for optimal success.

Committed to remaining abreast of technology in its field, Bossard Americas continuously invests in the latest automation systems available, passing on the benefits to its customers. “Everything we do is geared toward launching our customers and partners on the right foot with proper engineering, making sure their designs are optimized and that their material flow processes really work to make them as productive as possible,” explains Keri Miller, Director of Marketing.

One of Bossard’s most popular offerings, an inventory management system called Smart Factory Logistics (SFL), has been part of the company’s portfolio for a quarter of a century. Beyond inventory management containers, such as IoT-enabled SmartBins, SFL also provides advanced predictive AI capabilities. This involves collecting detailed information on customer consumption, logistics, and supply chain landscapes. Once the team has a firm grasp of these foundational details within a customer’s facility, systems can be automated to maintain stock levels perpetually with minimal human intervention. This reduces administrative burden for teams, as the sophistication of the product frees them up on multiple levels to focus on crucial customer-facing tasks.

Moreover, this system can now be integrated into Bossard’s Smart Factory Assembly (SFA) solution. Developed in response to ongoing industry labor challenges, this solution aims to provide a fast and efficient automated guide for new employees with little to no assembly experience. By offering simple, clear, digitized work instructions, it enables virtually anyone to build an assembly to exacting standards, making process replication straightforward. Consequently, digitization enables easy and accurate monitoring of material handling processes and system performance while simplifying the management of assemblies across different product ranges. This speeds up worker changeovers, provides clear labor support, and minimizes defect rates.

The solution is also fully compatible with a range of add-on systems such as robotics, drills, and camera systems, all focused on improving and maintaining quality standards while tracing all processes and providing the hard data needed to substantiate claims. Quality reports can be integrated into customers’ ERP systems, significantly minimizing reruns due to defects. Data provides vital metrics regarding improved efficiency, quantity surveying, labor time invested, and more.

“Not only are we providing the foundational process for the assembly—the elements that tie it all together—but we’re digitizing and connecting that process all the way through to the end, so every step is guided, traceable, and consistent,” says Miller.

To further ensure optimal outcomes on every project, onboarding clients is a thorough process. First, new facilities are carefully studied. Necessary elements, such as additional tools and workbenches with optional weight-managed scales, are provided to fully support the assembly process. This is followed by an integration process in which the Bossard team arrives on-site to provide customer teams with essential software training for complete control over all processes, including assembly programming. This gives end-users carte blanche over their systems, allowing them to set up any number of product lines based on their requirements and resources.

“We can provide a total solution as far as end-to-end service on assemblies goes,” says Steve Prostinak, New Business Development Manager.

Moreover, when the Bossard team is engaged early on in a project, its engineering team can ensure that every aspect of the product design is equipped with the correct fasteners for peak performance, longevity, and overall cost efficiency. “Depending on the level of automation, having the correct fastener for the job can be a real time-saver,” Prostinak advises. Considering redesign costs, involving the firm early in the development phase just makes good sense.

“Get us involved early so we can help you with the design, ensuring that you’re using the right components from the start,” says Doug Jones, Applications Engineering Manager. The company also assists with establishing optimal assembly strategies, including minimizing vibration issues and optimizing the torque used to fasten hardware. It also provides training, help with managing bills of materials, and more.

Looking forward to attending Automate 2026 in Chicago this year, the team anticipates meeting companies aiming to advance the technological aspects of their assembly lines, especially those looking to start small and scale as production grows alongside systems like SFA. “SFA enables you not to have to spend millions of dollars updating your factory floor and all of the hardware that goes along with it. It’s something that can be very easily integrated into your current workflow,” Miller says.

Beyond cost, the logic of such investments remains crystal clear: by leveraging Bossard’s full-service offering, OEMs can significantly improve their system reliability and bottom lines. To this end, Bossard Americas emphasizes the importance of incremental progress and enhancement. With assembly flow optimization at the core, partner customers would be hard-pressed to find a team better aligned with this mission than Bossard. By remaining relevant to their customers’ success, the company’s reach is growing steadily.

As most OEMs start to view assembly as a strategic discipline in response to speed becoming a growing factor in supply chain reliability, companies that recognize the cost of process variability in high-speed automation—caused by operator inefficiencies, supplier fragmentation, and inventory complexities—and choose to address the issue with such a complete solution set themselves on a new trajectory. Ultimately, assembly efficiency drives automation ROI, and achieving this requires expert engineering, advanced digital resources, and optimized logistics integration. Bossard Americas provides this sophistication and more.

The post From Hardware Distributor to Top-End Assembly Partner<p class="company">Bossard Americas</p> appeared first on Manufacturing In Focus.

Arguably, the biggest new development has been the company’s initiative of pre-engineered, configured-to-order (CTO) products to complement its customized solutions.

For Grotnes, CTOs offer multiple benefits including “faster delivery times, common platforms of parts, and spare parts that can be used across different models,” explains Vice President, Jim Zielinski. That said, customer specs sometimes demand a tailored approach, which is why Grotnes will never abandon custom work. “The custom side will always be part of our business. It’s our DNA… but the organization is trying to align itself around repeatable platforms,” he says.

Grotnes continues to build machines for four main technologies: expanding, shrinking, roll forming, and spinning. Expanding processes involve shaping metal parts for pipe couplings, jet engine components, metal containers, and the like. Shrinking entails the exact opposite procedure and aims to reduce and shape parts for motor frames, conveyor rolls, and exhaust components. Roll forming involves bending hoops of metal, while spinning is a metalworking technique based on mechanical rotation. Closing tools, used to seal or close items such as pail lids or the tabs on large-size paint cans, are also becoming a growing category.

Monumental as the introduction of CTO solutions might be, there have been other big changes at Grotnes as well. For a start, the company is going through “a digital transformation” that entails “the leveraging of AI where it makes sense in the business,” says President Mike Walker.

To this end, the company will soon launch Grotnes’ AI assistant, a tool that could be compared to Amazon’s AI-enabled, voice-led personal assistant Alexa, but for internal use only. “There’s no gateway to the outside world. It’s utilizing AI’s ability to search our databases, our files, our drawings, our pdfs, to be able to respond quickly,” explains Walker. “We’re very careful right now to adopt it where it really adds value to the company… We’ve spent a significant amount of time really focusing on, ‘How does it add value and help our customers at the end?’”

It is quite the leap for a firm that traces its roots to 1898 and a decision by one Charles Grotnes to open a machine works operation in Chicago. That business initially focused on manufacturing metal rings to hold barrel staves together. The company founder and namesake invented a time-saving machine to shape and stretch these metal rings to an appropriate size, and things took off from there.

At present, Grotnes serves the oil and gas, general industry, automotive, aerospace, rigid packaging, forging, and tanks and appliances sectors. The company uses the term ‘tanks and appliances’ to characterize its work for the power distribution and appliance markets with the tanks in question being metal storage containers.

“We do metal forming machines for large tanks that are typically used for isolation transformers, so there’s the power distribution angle, and then, from the appliance standpoint, tanks for things such as water heaters, drums for washers and dryers, dishwashers, and things like that,” Zielinski explains. Over the past year, aerospace and automotive generated the most business, a pattern that is likely to hold steady in 2026, he adds.

He has noticed something of a resurgence in the market for catalytic converters, the devices that reduce harmful exhaust emissions from combustion engines. Since large, commercial trucks would require huge electric batteries, thus limiting payloads, concerns about battery size have stalled the drive toward vehicle electrification in certain sectors. With gas and diesel-powered trucks still dominating, the demand for catalytic converters remains high. This trend is good news for Grotnes, which has been a pioneer in making machines that are used in catalytic converter production.

The company has maintained its ISO 9001:2015 certification and is gearing up to get certified when the new ISO standard (9001:2026) is released later this year. As befitting an ISO-certified company, quality assurance procedures here are rigorous. The company utilizes a coordinate measuring machine and other inspection equipment to ensure that all parts are shaped and sized correctly. Completed machines are subjected to rigorous factory acceptance testing procedures at the plant. If the machine achieves these benchmarks, it gets shipped to a customer, and the system is then put through site acceptance testing at the client’s worksite to determine that everything is in perfect working order.

“ISO is a very big part of our business and really drives the quality in our organization. We embrace that in a big way, especially the continuous improvement side of it. Every employee in our organization is able to submit improvement suggestions regardless of their position in the company,” says Walker.

The advent of a configured-to-order line is further proof of the company’s commitment to continuous improvement, he continues. Offering pre-engineered solutions will enable Grotnes to “focus on a standard design and continue to refine it for our customers’ needs and bring additional value by bringing costs down and benefits up,” he explains.

Company officials are well aware that excellent equipment requires servicing and upkeep. As such, the team kicked off a preventative maintenance initiative called the Grotnes Service & Spares Club last year. Customers who join the club receive discounts on spare parts, labor, training, phone and remote support, and other maintenance measures. The overall aim is to keep client equipment in excellent condition.

At the time we last spoke, the company maintained sales and service branches in Monterrey, Mexico and Atlanta, Georgia. While the Mexican branch is still flourishing, the Atlanta operations have been relocated to Niles. This transition has drastically reduced turnaround times for some products; solutions that might have taken a month to produce and ship in Atlanta now take maybe 48 hours, according to Walker. The company continues to ship products around the world and works with European sales partners as well.

Grotnes also runs a facility called Formitt Metal Labs as well as an in-house machine shop. Formitt Labs does prototyping and feasibility testing for customers as well as research and development. Recent equipment purchases for the machine shop, meanwhile, include a lathe and a wire electric discharge machine. The company’s five-year growth strategy includes the possibility of offering machine shop services as a separate business component for customers, a strategy that would build on already existing competencies. “We have customers who are not interested in a capital purchase and just ask us to do the production for them,” notes Zielinski.

In terms of promotion, Grotnes regularly attends trade shows. Last year, the company took part in FABTECH USA in Chicago—the top conference for fabricating, finishing, welding, and metal forming in North America, as well as Fabtech Mexico in Monterrey, Mexico. It also showcased its metal forming skills at the 40^th Space Symposium, a major aerospace event which took place in Colorado Springs, Colorado in April 2025. The company has revamped its website as well, with a view to adding updates regarding its configured-to-order (CTO) offerings.

All told, roughly 43 people work at Grotnes. Beyond the requisite education levels and skills, the company seeks applicants who can think on their feet and offer creative solutions. Personnel must be prepared to pivot in the face of challenges, think outside the box, and adapt to changing circumstances since “ours is a pretty fast-paced technology business,” says Zielinski.

Current challenges include dealing with the rising cost of materials, due in part to tariffs imposed by the United States and other nations. That said, “The biggest challenge for us continues to be the ability to hire the right people, and secondary to that, finding them. Every position in our company is really a skilled position,” states Walker.

To address this issue, the company instituted a four-year apprenticeship program which blends hands-on training with classroom learning. Apprentices attend evening classes at Lake Michigan College, which is based in Benton Harbour, Michigan and has a campus in Niles. The program just graduated its first apprentice, who specialized as an electrical technician, and apprenticeships are also available for machine builders and machinists. There are ongoing discussions about expanding the program to include engineering.

For a near-term forecast, Walker circles back to CTOs and AI. “Completing our journey on the CTOs is really critical to us,” he shares. “It’s not something that’s going to happen overnight; it’s not something that’s quick, because it’s got to be right.”

As for artificial intelligence, “We’ve come up with some pretty interesting initiatives,” he says. “Three years from now, I think we’ll [have a lot] to talk about… We believe it’s going to help us tremendously.”

The post Making the Machines that Run Industry<p class="company">Grotnes</p> appeared first on Manufacturing In Focus.

The owner and his staff make it their personal goal to genuinely enjoy every day at work. By hiring quality people and providing them with quality equipment, this company has reached heights its founder could never have imagined on the day he opened its doors for the first time.

Schlabach dreamed of “working in metal fabrication surrounded by great people,” since childhood. He would never have dreamed what good fortune awaited after a significant drop in hours at his job in the recreational vehicle (RV)/mobile home industry, which took a downturn around 1999. The solution was to offer his services as a volunteer to people with home-based businesses. One man he met used fabricated metal components for equine uses. After a day of painting these, the young entrepreneur offered to make and deliver those parts pre-painted, as he was better equipped at home to do a good job. This was the start of a successful business.

“I went home, and I bought a little bandsaw from Northern Tool out of a catalogue. I had a benchtop drill press, and I bought a welder, and I taught myself to weld. I found enough work to keep me busy,” Schlabach says.

Even though it was a financial struggle, he didn’t mind as he was happy with his new occupation. Prototyping followed, and after a year or two, a larger garage. Schlabach then hired a few assistants—some of whom are still with the firm over 20 years later. He continued working his day job and returned to join his team in the afternoons and evenings. His day job employer later gave him the opportunity to fabricate steel components for RVs.

Business continued increasing, from supplying one RV plant to another, until the recession of 2008 hit. The team was expecting business to grind to a halt again, but the opposite happened. As steel prices doubled, the opportunity to quote for contracts that would normally have been reserved for a select few in previous years suddenly became available as financial strain sent companies in search of significantly lower prices. Suddenly, a large company was willing to give Schlabach an audience, and the team set out to prove itself.

By 2009, when the economy and steel prices started normalizing, the fledgling company had secured itself a place of trust amongst some of the area’s leading component fabricators for the RV industry. Since then, Rock Run Industries saw consistent 35 percent growth for 13 years.

“I kept pouring all the profits back into the business, buying more equipment, which is truly what I like to do,” Schlabach says. “I love going to work. I love working with great equipment. I love working with great people. I got to do exactly what I wanted to do in life.”

He admits that his original lack of knowledge about scaling the business, budgets, goal setting, and other standard business practices—and his subsequent solutions—now defies conventional wisdom. Yet, by staying the course, he came through every challenge with more great equipment and many stories to tell. Once, after hiring a consulting company to analyze the company’s systems with a view to optimize, Schlabach was informed that he had no ordinary company. Asked for clarification, the consultants told him that “normal” businesses have a difficult time receiving products from their vendors; they have a tough time hiring help; and they have an even tougher time showing a profit.

“I said, ‘then why would I want to be normal, if that’s what you’re telling me normal is?’” he says. His response to the value of support could surprise some folks. “I relied on my wife, and I relied on my Savior, my God. The Bible is full of business advice, if a person truly cares to go there for advice and trust in it,” he says.

Schlabach considers his wife Jane to be instrumental in the company’s success. As his confidante, soundboard, and biggest supporter, talking to her gave this natural leader an opportunity to work through challenges and develop solutions. “Thank goodness she was there for me. She’s still there for me. It’s something that most businessmen overlook, the support that they can get from their wife,” he says, praising her poise, intelligence, and beauty.

As for his efficient business systems, paying companies and his people well and on time has proven invaluable and has, surprisingly, become the puzzlement of many, leading a few people, including a chartered accountant from Pennsylvania, to extensively quiz the owner on his secret. “Well, it’s just too darn simple,” the accountant said. “Most people will never believe that.” Schlabach is generous with his formula and describes it as follows:

If a customer buys a part worth $10 in labor value, 75 percent, or $7.50, goes to the employees as a split labor rate. The other $2.50 goes to the company to cover overhead costs. When the company builds over 124,000 parts in a week, the employees earn 75 percent of the labor value of all those parts and the remaining 25 percent goes to the company. Therefore, if one person builds 10 parts per hour at $10 per part in labor value, $75 dollars goes into the labor fund, and $25 goes to the company. Using this system, Rock Run pays employees more than its competitors. The best part is when the employees find efficiencies and ways to produce more than the expected parts per hour. Then their pay goes up per hour but so does the company’s allotment for overhead costs. The company also takes its infrastructure output capacity into account. “In order to cover my overheads and raise the employee’s pay, I might have to buy my people better equipment,” Schlabach says.

In this way, people can then deliver more units in a day. “I do everything I can to make sure that they can make as much money as possible, and if I do that, it takes care of every other problem I have,” he says. The result is happy employees, great cash flow, and better procurement.

With the company’s real profit opportunities residing in the metal it purchases, the more metal that passes through and out of its doors, the more profit it makes. “I make money on every pound of steel that goes through here,” Schlabach says, underscoring the fact that, in this way, a comparatively small outfit moves incredible volumes of metal while retaining staff, covering overheads, and increasing profits. “Everybody wins.”

This approach ensures that staff members are happy, clients are happy, and everybody else in between is happy—all while profits are coming in. For this reason, Schlabach sees no need to implement draconian rules and greedy incentives to squeeze even more out of a system that is very clearly working. Looking back, he shares earlier experiences that shaped the company. Even though the business was making plenty of money, living frugally with nine children meant no splurging on luxuries. There were few vacations, no second homes, and no prestigious vehicles to flaunt their newfound success for the Schlabachs. His advice is clear: to make a company work, ensure that you enjoy the work, because financial gains are hard-earned and slow to materialize. Without enjoying the process, life will lose its luster.

Highlighting that another overlooked business resource is a good banker, Schlabach advises trusting bankers for financing, as they are not at liberty to hand out loans that risk turning bad. “They’ve seen companies that have flourished, and they’ve seen companies that have failed; they know the warning signs. Don’t be afraid to sit down with your banker every three months or six months and hear their side of the story, even if you don’t like what they’re telling you,” he says, pointing out that bankers can be intimidating when one is young, but that they really are valuable allies.

On the topic of financing equipment, this leader advises taking loans during low-interest periods but cautions that paying such loans off early could work against one when cash flow is better directed elsewhere to cover operational costs. Moreover, he believes it is important not to have all equipment financed. By taking what he calls a stress analysis, Schlabach recommends calculating whether the company could survive a black swan event with the amount of debt it holds or not. If the answer is negative, it is time to improve the strategy by turning the situation around. Curb rapid growth and be watchful of finances when clients pay every 60 or 90 days. It is much easier to grow rapidly when customers pay in 30 days or less.

With the majority of RV fabricators being located in Elkhart County, Rock Run has grown tremendously in revenue. While this field remains the company’s main market, it recently signed a contract with Full Swing, a golf simulator outfit. Even more recently, the company started seeing sales representatives arrive at its doors from 250 miles away with fabrication requests. Following COVID-19, when the RV industry skyrocketed and before settling down again, the company decided to start reaching out to contract manufacturing customers to expand its reach. This gave it a head start on establishing trust in new markets at a time when things are looking up for American fabrication.

Always prepared for any eventuality, Rock Run continues to keep costs consistent for customers by maintaining a significant pre-purchased inventory. While this demanded large capital investment, it now means remaining competitive price-wise. To this end, Schlabach counsels vigilance. “There is never a good time to not be paying attention,” he says of the market.

In the last two years, the company nearly doubled its workforce with the appointment of 70 new people, added to its existing team of 100. And as mentioned, paying people more than the standard wage is part of the company’s strategy to maintain an expert workforce. “Our guys make good money. [They earn] very high wages compared to the industry, and they like that. They appreciate that,” Schlabach says. It also means that people are committed to maintaining the happy, respectful equilibrium for which the company is known. Not being driven by money but rather loving to be around the team allows the business to serve as a force for good.

“I never really thought about how much we would grow or what our sales would be or what we would do—I just wanted to work with great people,” Schlabach says. “I’ve been fortunate in that aspect, that it’s happened.”

Today, five of the nine Schlabach siblings have joined the company and will be invited to each purchase 10 percent of the company when they reach the age of 25. “My children are very talented. They have great minds. That’s a blessing, not everybody can say that, but they have great minds. They’ve taken lots of interest, and the current management team acknowledges and appreciates that,” their father says.

As the next generation takes the reins, Fritz Schlabach plans on responding to the call of distressed companies in need of consultation with his expertise as interim CEO to help turn their fortunes around. As a fit 50-year old who gets “a little depressed when there is nothing to solve,” there are clearly many years of great service ahead for this man with his singular vision for achieving good in this world.

The post Solid as a Rock<p class="company">Rock Run Industries</p> appeared first on Manufacturing In Focus.

As Canway Equipment marks its 40^th anniversary, the milestone offers a moment to reflect not only on where the company has been, but on how it continues to adapt and innovate in an increasingly complex manufacturing landscape.

“The company was started in 1986 by two gentlemen, Paul De Vries and Adrian Hovestad, and when they started, they were primarily involved in hand trucks and ladders; that was their main focus,” says Roland Verhey, Director of Sales and Operations at Canway Equipment.

What began in a small facility has since grown into a modern manufacturing operation powered by advanced automation, precision engineering, and a deeply embedded culture of safety, quality, and customer responsiveness.

In its earliest years, the company operated from a modest location, producing equipment in small batches, often building “ones and twos” to meet immediate customer needs. By the 1990s, increasing demand and expanding product lines prompted a move to the company’s current facility, a shift that laid the groundwork for decades of sustained growth.

A significant turning point came in 2001, when the business was acquired by its current owners. The transition brought new strategic direction and operational focus, enabling the company to scale its capabilities while preserving its core values of craftsmanship and reliability.

Verhey, who joined the company five years ago, has had a front-row seat to Canway’s latest phase of expansion. He credits much of the company’s evolution to continuous improvement across both design and production. “As the volume increased, it gave us opportunity to improve on the design of many of the different components and find efficiencies,” he explains. “Once you start building 50 at a time, you can do things quite a bit more efficiently.”

This mindset, that growth should unlock smarter processes rather than simply more output, has driven many of Canway’s most transformative investments. Among the most impactful upgrades in recent years was the installation of a fully integrated powder coating line, which fundamentally reshaped Canway’s production flow.

Before the upgrade, the company relied on a wet-based enamel paint system that required large drying areas and careful handling to prevent surface damage. Products often spent up to 24 hours drying, tying up valuable floor space and introducing environmental and safety challenges. The new powder coating line changed everything. “More or less, the ladders would be hung on the line, they would get washed and rinsed and dried, painted and cured within about two hours,” Verhey says. “As the products would come off the line, we could then assemble with wheels and casters, package it up, and roll it onto a truck.”

Beyond dramatically shortening production cycles, the new line improved coating durability and reduced environmental impact. It also pushed design teams to rethink product geometry to accommodate hanging, drainage, and curing processes, a shift that elevated engineering precision across the board.

The result: a leaner, faster, safer, and more sustainable manufacturing workflow that positioned Canway for its next decade of growth.

If the powder coating line represented operational evolution, the pandemic-era supply chain crisis triggered a manufacturing revolution. Historically, Canway produced perforated ladder treads in-house, while diamond channel grating, a key ladder component, was sourced from China. When global shipping delays stretched lead times beyond a year, production bottlenecks forced leadership to rethink their dependency on offshore suppliers.

“We had containers of treads floating off the coast, waiting for availability at the port,” Verhey recalls. “During that time, it really forced us to rethink our process of importing these treads.”

The solution came in the form of a fully automated step manufacturing line, installed in 2024. The new system allows the company to produce both perforated and diamond channel treads entirely in-house, using locally sourced steel coils.

This strategic shift delivered multiple benefits: shorter lead times, improved quality control, supply chain resilience, and reduced exposure to global disruptions. It also marked a major technological leap, introducing advanced automation into a process previously dominated by aging equipment.

Today, one operator can oversee the fully automated line, producing large volumes of precision-formed treads with remarkable consistency, a powerful example of how necessity can fuel innovation.

At the heart of Canway’s business lies its core product: rolling steel ladders, which account for roughly 70 percent of production. While ladders may appear simple, Canway’s engineering approach reveals a sophisticated blend of durability and ergonomic design.

One key differentiator is the company’s fully welded construction method. Unlike bolted systems that loosen over time, Canway ladders are welded into rigid, integrated structures that arrive fully assembled. “The main thing that differentiates us in the ladder world is that we feature all welded construction,” says Verhey. “Over time, it’s a more durable ladder because there’s not all these fasteners that will slowly loosen. It’s sturdier, more rigid, and easier to install.” This design philosophy reduces on-site assembly and delivers a safer experience for end users, many of whom rely on Canway’s ladders in demanding industrial environments.

Some of Canway’s most successful products were not born in design labs, but in direct response to customer challenges. One standout example is the Safeguard Ladder, developed after a customer requested a safer platform solution that eliminated fall risk at the top of the ladder. Traditional chains and barriers proved cumbersome, so Canway engineered a double-gate system that automatically closes behind the user.

“Once you walk through the gate, it self-closes behind you. When you’re on the top platform, you’re safe, you can’t fall down the ladder section,” explains Verhey.

Originally created for a single client, the product quickly gained traction across multiple industries, ultimately becoming a full product line, a testament to the company’s customer-driven development model.

Indeed, customization lies at the core of Canway’s value proposition. Rather than forcing customers to adapt to standard equipment, the company engineers solutions around spatial constraints and safety requirements.

Cantilever ladders are a prime example. Designed for environments where obstructions prevent standard ladder placement, these models feature extended platforms balanced by counterweights at the base, enabling safe access beyond the ladder’s footprint.

Beyond ladders, Canway’s customization expertise extends into material handling solutions, including lift baskets, engineered bins, service carts, and specialty platforms. These products, too, often emerge from customer requests that reveal broader market needs, and the company’s in-house engineering and fabrication capabilities allow it to respond quickly and deliver highly tailored solutions without compromising quality or lead time.

For Canway, quality assurance is not an isolated checkpoint; it is embedded throughout the manufacturing process. Each ladder passes through multiple inspection stages, from component assembly to final packaging. Operators review parts at every station, while dedicated QA checks occur both before painting and after final assembly.

“A ladder must ensure the safety of its user,” Verhey emphasizes. “If there’s a missing weld and a tread fails, that could be catastrophic. We take quality in that sense very, very seriously.”

This rigorous approach ensures that every product leaving the facility meets stringent safety and durability standards, a non-negotiable expectation for customers in industries such as healthcare, manufacturing, construction, and energy.

Canway’s success is anchored in its people. With a workforce of approximately 40 employees, 30 in manufacturing and the remainder in engineering, sales, and administration, the company operates on a culture of transparency and long-term development. Rather than simply filling positions, Canway invests in career pathways, aiming to cultivate today’s operators into tomorrow’s leaders.

“We’re always looking at skilled labour and hiring for the future,” says Verhey. “The people we hire today, someday we want them to be lead hands and eventually leaders.” This philosophy extends into training programs and skills development, ensuring employees understand both current expectations and long-term opportunities.

As manufacturing technology evolves, Canway is embracing automation strategically—not to replace people, but to enhance efficiency and consistency. The automated step line marked a major leap forward, and future investments are already underway. Robotic welding stands out as the company’s next major frontier, offering opportunities to increase throughput while reducing physical strain on skilled welders.

In parallel, plant safety upgrades, including modern shears and press brakes equipped with light curtains, reflect Canway’s commitment to protecting its workforce through intelligent engineering. These investments signal a forward-looking mindset, positioning Canway to compete effectively in an increasingly automated global manufacturing environment.

Of course, distribution plays a pivotal role in Canway’s business model. With ladders that are large and costly to ship, the company relies on a trusted distributor network to provide nationwide reach and logistical efficiency. Rather than competing with its distributors through direct sales, Canway operates exclusively through these partnerships, a strategy rooted in trust and shared success.

Through distributor feedback, Canway also gains invaluable insights into customer needs and industry trends in real-world environments, which directly inform design improvements and product innovation.

Looking forward, Canway sees strong opportunity in expanding its material handling portfolio, particularly in service carts, dollies, and retail equipment, sectors where quality and customization remain in high demand. By leveraging its engineering capabilities and manufacturing expertise, the company aims to fill market gaps with domestically produced, high-quality solutions that outperform imported alternatives. At the same time, ongoing investments in automation and robotics will continue to enhance operational efficiency, enabling Canway to scale without sacrificing craftsmanship.

After 40 years, Canway Equipment Mfg. Inc. stands as a testament to what sustained innovation and operational discipline can achieve. From its origins in hand trucks and ladders to its present role as a technologically advanced manufacturer serving industries across Canada, the company’s journey reflects a deeper commitment to safety, quality, and solving real-world challenges.

As Canway enters its fifth decade, the mission remains unchanged: build better products and continuously raise the standard for what Canadian manufacturing can deliver.

The post Engineering the Future<p class="company">Canway Equipment</p> appeared first on Manufacturing In Focus.

“We focus on philosophy in design first, so we can then enhance products in the very dynamic office world that we’ve lived in since immediately pre-and post-COVID,” explains President and CEO, Bill Melnik. “Our goal has always been to build safe, sustainable, healthy, and productive environmental products.”

Tayco is upfront about promoting its key values, including inclusivity, sustainability, and fostering a strong employee culture. For three years in a row, Tayco has been certified by the Great Place to Work® Institute Canada and remains widely admired for its levels of inclusivity, equity, personal satisfaction, and employee engagement.

Strong leadership
In October 2022, Bill Melnik became Tayco’s CEO, succeeding Kevin Philips. Originally founded in 1976 by Kevin’s father, Phil, the company started producing value-conscious, space-dividing office furniture panels. A recent immigrant at the time, Phil brought the concept of local-supply, Canadian-made craftsmanship to the market.

“Their early success was based on building strong customer relationships, almost direct to customers and resellers,” says Melnik. “That culture still exists and is defining for Tayco today. We produce locally made Canadian products and ship them around the world. We value our strong customer relationships, which are a core element of our success. And of course, our craftsmanship helps keep that legacy alive.”

Adapting to market needs
The office environment has transformed over the decades, and Tayco continues to create and modify products to meet evolving needs. In the ’70s and ’80s, office panels were heavy and featured wood trim, but as time went on, Tayco introduced more value-added products to the market. Hiring additional workers with new skill sets, the company created office panels using materials like aluminum and steel. These changes saw the development of Tayco’s modernized Cosmo Integrated Panel System, which is customizable, features a highly functional tilt-and-frame design, and utilizes modern finishes such as glass, acrylic, metal, fabric, and laminate.

“Now that same panel—with a different kind of engineering structure and a different design—can have a wood bottom,” says Melnik. “It can have two kinds of different fabric on the top, and on the other side, it can have a completely different mix of fabric and/or other materials as well. So that’s where the advances have taken us.” Today’s panels are highly design-focused, suit a range of price points, and are customizable.

The company’s original panelling line was one of the pillars of its success and remained in production until around 2011. Tayco continued to build robust lines from 1976 to 2012, including Metro, previously known as Metropolis. The private Metro line is sleek and elegant, and includes storage, desking, and Tayco’s Volley Height Adjustable Tables casegoods furniture.

Recent years have seen the company greatly enhance its product lines to meet today’s office and home office demands, calling for features like ergonomic and height-adjustable solutions, provisions for power and communication, enhancements to original panelling products for privacy, and noise reduction.

Tayco continues to work closely with customers to create flexible, modular, long-life products with clean aesthetics that are highly adaptable and prioritize functionality. But Melnik observes that the sector is far from static. “I think it’s accurate to say that, since the COVID years, the office environment has been a truly dynamic market, particularly in furnishings,” he shares.

The office environment is indeed constantly changing, with younger people entering the market who may work solely in offices, solely at home, or a combination of both. “Our products focus on solutions for all those kinds of markets,” says Melnik.

A great place to work
Along with its superior office products, one of the first things Melnik noticed when he became Tayco’s CEO was the company’s outstanding workplace culture. As he said in 2022, “The entire team champions the brand and is passionate about providing the ultimate products and services to our customers. The Tayco culture truly demonstrates how a positive workforce directly correlates to employee engagement. I am proud to represent an organization with such a strong culture and enjoyable atmosphere, and look forward to watching it continue to blossom.”

The many skill sets of Tayco workers include welding, steel working, upholstery, fabric assembly, and applications to produce custom and semi-custom products. Some staff have been a part of Tayco since the ’70s and can share their wealth of knowledge with younger employees, a dedication that is a testament to the company’s culture. “That word’s really thrown around these days, but there is a culture of respect for our employees and customers, and respect for all aspects of doing business. Employees are valued for their input, feel comfortable, and are part of a long-term, safe culture,” Melnik says.

Indeed, Tayco regularly reaffirms its core values to its team and others: ownership, progressive [mindset], enjoyable experiences, and efficiency. These values have led to Tayco’s consistently being named to the Best Workplaces™ in Manufacturing list, based on direct employee feedback and an independent analysis by Great Place to Work®.

Along with its employees and customers, Tayco is also proud of its robust dealer partner network and independent representatives across North America. In the past few years, the company has stepped up efforts to sell products to clients not just in Canada and the United States but also in Mexico, the Caribbean, emerging markets in the Middle East, and key countries in South America.

“Our clients are the Who’s Who of the business clientele of any city and any country,” says Melnik. “But ultimately, they are our partners. They include corporate and commercial office spaces, from banks to legal firms and insurance companies. This broadly includes education, financial sectors, automotive sectors, and any and all levels of government,” he explains.

Ethical and sustainable
In today’s world, sourcing and buying Canadian-made products is more important than ever, and Tayco buys local materials to use in production whenever possible.

“Canada can be very proud of itself,” comments Melnik. “We are leaders in wood and panel products, bar none.” Purchasing most of its steel products locally, the company processes them internally in its own steel facilities, resulting in added value directly from Tayco and good, solid jobs for employees. “It is a strong selling point that we are a North American-based company,” says Melnik. “Our Canadian customers appreciate that we are Canadian and a Canadian-focused manufacturer.”

In January 2024, Tayco released a document on Fighting Against Forced Labour and Child Labour in Supply Chains detailing the company’s commitment to ridding its supply chains of every incidence of forced labour and child labour. Such vigilance means continually monitoring its supply chain, structure, and activities for any occurrence, or even the slightest warning signal, of these activities.

Melnik notes that sometimes there is a “wilful blindness” about the purchases we make—including a shallow view of the cost: if something doesn’t cost much, it can be replaced in the future, and it doesn’t really matter where it comes from. “This flies in the face of the value statement Tayco has, as well as its core values,” he stresses. Tayco expects its suppliers and others to be consistent with their reporting and to adhere to guidelines against forced labour. “It is tragic to think that, in the world we live in today, children would have to be exploited for the benefit of some cost-savings in North America,” he says. “For me, it would be a personal slight to think we are selling something because a child made it, that they could be exploited because it is made in another country. And if we brought it into our own country and profited on it, this goes against us as a company, as Canadians, and against me personally, to think that is something we would tolerate. I say no.”

50 years of success
To succeed in business for half a century is a major milestone. This year, Tayco will celebrate its dedicated employees with a focus on the generations of families who have worked there, along with acknowledging customers and representatives who have been with the company for decades. This will see different marketing campaigns with a focus on voices that have made the company the success it is today.

“Our employees do truly live and breathe our core values every single day,” says Emily Boland-Slinn, Director of Marketing and Communications. “In turn, that helps our dealer partners—the people we sell to, our resellers—live and breathe those core values as well, and have trust in us. So we will be acknowledging that through social media, different marketing initiatives, and events throughout the entire year.” And to acknowledge its milestone, Tayco will release a special new 50^th anniversary logo.

Today, the Tayco team includes about 240 staff members and around 30 reselling and independent agents. And while roles vary widely from the factory floor to the office, they all have one thing in common: continually striving to produce the best, sustainably made, ethically produced office furniture on the market.

“When you think about 50 years, it’s not just a corporation that has survived over 50 years; it’s a corporation that has significantly grown, changed, and is continuing to do exactly that after 50 years,” says Melnik. “It represents 50 years of substantially 100 percent Canadian jobs. Although some of our selling partners and agents are elsewhere in the world, there is a substantial Canadian job component. There are 50 years of trust, and I don’t think you stay in business that long without developing trust,” he says.

“If we were not consistent and trustworthy and did not have a progressive mindset, we wouldn’t be selling to customers after 50 years, nor to people who buy our products and resell them. They would just move elsewhere. It’s 50 years of showing up—consistently coming back and being there for all of our customers, all our resellers. So here we are. We are not looking back on 50 years, but focusing on setting the stage for the next 50 years. We are proud of that, we are thankful, and we congratulate the whole team for the momentum we’ve created.”

The post Quality People and Products Make Quality Years—50 of Them<p class="company">Tayco</p> appeared first on Manufacturing In Focus.

Except for food and medicine, then-President John. F. Kennedy banned trade with Cuba in February 1962. By March, the U.S. was preparing “a new intervention against Cuba,” with additional bans put in place on all Cuban-made goods. Tensions increased, ultimately culminating in October’s Cuban Missile Crisis.

It was against this backdrop of global uncertainty that German businessman and entrepreneur Ortwin Stieber decided to diversify. Founder of the Munich-based transmission company Heynau Antriebtechnik, Stieber began investigating other countries in which to do business, including Canada. Invited by the Kitchener Chamber of Commerce to visit the Ontario city, Stieber soon purchased an industrial property and founded a gear manufacturing business, calling it Ontario Drive & Gear Limited (ODG).

“The reason he called it Ontario Drive & Gear was so that he knew where it was and what they did,” says ODG’s Director of Program Management, Stephen Brown.

ARGO
In 1967, the year of Canada’s centennial, the company moved to New Hamburg, Ontario. ODG was manufacturing steering transmissions for an amphibious all-terrain vehicle company when that business failed. ODG was left with a number of transmissions and no customer. This led to Stieber’s building his own amphibious all-terrain vehicle named ARGO.

Continuously refined over the decades, ARGO remains, according to the company, “the world’s most successful amphibious vehicle” in terms of units produced. Other models were introduced, including Centaur (known as ARGO’s big brother), the three-wheel ATV Taurus, and Artemis, a robotic concept rover for exploring the Moon and Mars.

For a time, Ontario Drive & Gear and ARGO were under one roof. The ARGO business was cyclical, explains Brown—busy in spring and fall with hunting and fishing, but slowing down over the winter months. Not wanting to lose skilled labour, the company began looking for outside customers. “Over the years, the machine shop side of the business started to grow and grow,” says Brown. “In 2000, we built the gear division building, because we grew both the ARGO side and the gear side of the business beyond the walls of the one building. Today, ARGO makes up about 15 percent of our manufacturing capacity; 85 percent of what we do is work other than ARGO.”

In the gear division, the company builds transmissions and some mechanical components for ARGO, while the rest of the vehicle is made and assembled in another building. While some materials, like tires and engines, are purchased, ODG does everything else, including vacuum forming of the upper and lower vehicle bodies, welding the frame, powder coating and painting, final assembly, and shipping directly to dealers from the factory.

A different breed of machinist
Family-run for many years and under the long-time leadership of Ortwin’s son, Joerg Stieber, ODG is today under its second private equity ownership. With a dedicated team of about 200 staff members between its two facilities, ODG’s work demands a different breed of machinist. “Although it’s manufacturing gears, the type of machining is different,” says Brown. “Knowledge requirements for gear manufacturing is specialized, and the equipment itself is highly specialized as well.”

Like many other companies employing highly skilled professionals, Ontario Drive & Gear is facing challenges arising from retiring workers. To address this, the company is striving “to bring knowledge to the next generation,” says Brown. “It’s not something where you can sit in a boardroom and come out being a gear expert, but developed over a long period. It’s a learning exercise—hands-on, working on machines—and requires a lot of investment in people. Since few educational institutes teach gear manufacturing, a lot of what we do is develop good machinists into good gear manufacturers. There’s a lot of in-house training, and we rely on some of our machine manufacturers to provide some training.”

The recently renamed Motion and Power Manufacturers Alliance (MPMA)—formerly the American Gear Manufacturers Association (AGMA)—provides some training as well. “We have to grow our own talent in many respects,” says Brown.

Local business, worldwide reach
Through its global dealer network, the company ships to customers across North America, South America, and Europe. Customers choose to work with ODG for many reasons, including the company’s outstanding work, customer service, and reduced lead and travel time. “We are a very high-quality, high-skilled manufacturing facility, where the product we put out the door is the best quality,” Brown says. “If there is a problem, we are very responsive. If there is a design change requirement, we are very responsive. And if there is a demand change—whether they need to expedite or draw back—we are very responsive. We can be on site with most of our customers within 24 hours if need be.”

Sometime, customers come to ODG with finished drawings; other times, they arrive with just an idea. In either case, the professionals at ODG can help. “We manufacture to print or help develop a concept,” says Brown of the company and its in-house design capabilities. “It just depends on the scope and size of the project. We like to call it design, manufacture, assemble, and test. We are a custom gear shop, small to medium production volume. We are niche, and we do very high-precision work and lower volume than most gear manufacturers do.”

Decades of gear knowledge, a high level of service, in-house engineering and design, and the ability to pinpoint potential issues puts ODG at an advantage. Sometimes customers come to the company with an existing design that just doesn’t work. Other times, the design works, but not as efficiently or quietly as it could. In those cases, ODG’s talented engineers can take a client’s existing design, perform a gear analysis or assembly analysis, and suggest small changes to the gear geometry could take the decibels down to an acceptable level.

“It really depends on what the customer needs,” Brown explains. “Is it weight savings? Is it cost savings? Is it noise concerns? And that’s where we lean on our design expertise, our capabilities, our talented team members, over 60 years of manufacturing experience, and some of the latest equipment to develop a better product for an existing customer.”

As a production facility, ODG typically pursues production volumes, or projects that will have a future in production. This can range from as few as one or two pieces in the prototyping and pre-production phases up to about 100,000 pieces a year, depending on the product, market, and customer needs. “Much of what we do today is lot sizes from 50 pieces up to 3,500 pieces a lot, and annual volumes ranging up to 35,000 is fairly common,” says Brown.

Gears range in size from 6mm to 500mm in diameter. Although most are made from ferrous or non-ferrous alloys which are case-hardened, ODG will also handle plastics, bronze, and brass. “Gearing is about carrying torque and power, so really soft materials are rare in the gear industry—it would be niche applications for actuators. The vast majority, probably 98 percent of what we do, is ferrous metals that can be case-hardened,” explains Brendan Purcell, Business Development Manager.

The solutions customers are seeking
Ontario Drive & Gear considers itself a ‘Customer first’ business, Brown tells us. “We like to be a solutions provider, and realistically, if it’s outside of our scope of internal expertise, we can help you source whatever you need.”

The gear industry is complex, and investments can be significant for companies seeking to be a jack of all trades of gear manufacturing. In approaching its customers to determine their needs, the ODG team—who refer to themselves as “a bunch of gear geeks”—listens to their customers, their requirements, and any existing or potential design issues.

“We aren’t just a machine shop; we are much more than that,” says Purcell. “We have a design, manufacture, and assemble philosophy here. So we can help with everything from black box design, where the requirements of the mechanical system itself are unknown, all the way through to production, or anything in between. And for the size of our company, we are a large supply chain both domestically and internationally.”

Gearing up for the future
In business for 64 years, Ontario Drive & Gear continues to grow mindfully. Many times, the runway for projects is very long—sometimes six months to a year or longer from the quoting stage to production. And continuing to invest in equipment means the team looks not only for replacements, but for the next advanced technology. “Parts are getting more complex,” says Brown. “That’s the niche environment we live in, and we have to have specialty equipment to do it. It’s about investing in the people as well.”

Owing to the company’s location, ODG is able to draw on the next generation of talent from institutions such as the University of Waterloo and Conestoga College. At any one time, the company has several co-op students from the University in various departments including manufacturing, engineering, and quality engineering. “We are also going further, planting some seeds with the local school board here, to see if we can get some interest at the high school level as well,” says Purcell.

Although the company advertises through its website and LinkedIn page, ODG finds word-of-mouth is still its best promotion. “We attend trade shows, but we don’t necessarily show at them,” says Brown. “Having these connections—and with our sister company in the off-road recreational space—we often say, ‘Come to our factory, see what we do and how we manage our processes.’ We’re not just gear manufacturers; we are also gear users. We put these products into our own vehicles, and we know how they work, and we know the legacy of them in the field,” he says.

“Once we have someone interested in engaging with us on a project, we like to get them into a plant, introduce them to our processes and our people, and I think that’s what really draws people to continue to work with us. Our best marketing tools are our factory and our people.”

The post Proven Products, Superior Service<p class="company">Ontario Drive & Gear (ODG)</p> appeared first on Manufacturing In Focus.

Calling Galco a powerhouse of ingenuity is no overstatement. Over the past six years, the company, known for supplying factory-authorized industrial electrical and electronic automation, controls, and component products, has delivered sustained growth amid the economic volatility and supply chain instability that have reshaped global industrial distribution since 2020.

Galco’s differentiator is straightforward. It positions itself as a premium problem solver for customers facing maintenance, repair, and operations (MRO) challenges. Headquartered in Madison Heights, Michigan, the company supports Tier 1 suppliers and original equipment manufacturers (OEMs) across industries, including automotive, agriculture, food and beverage, oil and gas, data centers, and beyond. Galco provides mission-critical components and the expertise required to keep operations moving.

Closer to clients in every way
Backed by its six brands and nearly 300 employees, Galco’s team has built a reputation for continuous improvement. This is measured not only in internal efficiency, but in customer proximity and responsiveness.

On one hand, the company has broadened its operational scope while reducing the geographic distance between its team and customers. On the other hand, it has invested significantly in its omnichannel presence, creating a seamless, consistent experience for customers both online and offline. These investments make information and support easier to access through intuitive channels and streamline purchasing for faster, hassle-free product acquisition.

In step with the times, Galco has made some major investments in AI. Chief Information Officer Joe Garzia emphasizes the importance of distinguishing legitimate new pathways from no-go zones within the technology. “Our focus on AI is to be open to opportunities, but cautious,” he says. “A lot claims to be AI these days, but it is just buzzwords.” The priority is improving customer experience while keeping systems secure and proprietary to Galco.

As the organization implements new technology across departments, the finance team has overseen meaningful upgrades. These upgrades automate repetitive tasks so staff can focus on higher-impact work. At the same time, the company remains vigilant about cybersecurity and information security while pursuing initiatives designed to improve how customers get answers and move from need to solution.

Galco’s most recent addition in this area is a chatbot, currently under development, which will soon offer an extra layer of quick-access support, providing customers with faster information and expedited service. This gateway boasts yet another layer of support in the form of agents ready to assist when a request is beyond the chatbot’s scope. The company is also building an automated quotation capability aimed at reducing turnaround time and improving speed-to-order.

Importantly, AI now plays a new role in Galco’s marketing and service delivery—powering smarter product recommendations that improve customer outcomes. “Today, the bar has been raised so high—everyone expects an Amazon-type experience when shopping online,” says Allison Sabia, President and Chief Executive Officer, of the company’s commitment to customer care. “That’s why we use what customers already have in their cart, along with what’s popular on our site, to recommend the items that pair best—so people can quickly find what goes together and finish the job with confidence. I would say we lead in that.”

In search of value for clients
Galco’s value proposition is extensive, starting with inventory depth that helps customers avoid tying up capital in stock. Its highly skilled, sought-after technicians are also well-versed in repairing rare, sometimes vintage equipment that is difficult or impossible to replace. In addition, Galco offers custom systems improvements and retrofits wherein the team creates electronic drives that function with customers’ existing controls.

Extending Galco’s expertise beyond the website and into a format customers engage with every day is its social media presence, part of a broader effort to create thought-provoking content across Galco’s digital channels, including YouTube, TikTok, and Instagram. From how-to instruction to quick tips and product spotlights, these channels illustrate the tremendous value and depth of Galco’s resources and credibility with customers.

While all these efforts certainly drive growth, Galco’s main means of expansion is through acquisition. As the company already serves all of North America, Thomas Muldowney, Vice President of Sales and Business Development, and his fellow leaders aim to broaden their presence further and extend capabilities through aligned additions to the portfolio.

“Galco’s growth strategy is about extending an already strong North American platform,” Muldowney says. “We focus on acquisitions that add technology, expand capability, and align with how customers want to buy and be supported.” Beyond reach, the company looks for businesses that strengthen services and technical competency so it can deliver a broader set of solutions across industries.

Driven by this vision, Galco is always keen to add well-aligned businesses to its portfolio. Founded in Michigan in 1975, the company began taking steps to expand its presence about five years ago. Reaching from the East Coast into the Midwest and growing southwards from there, it now defines “going the extra mile” as meaning “being within easy reach of clients.”

“We have so many different verticals here, from repair teams that can leverage Galco’s parts inventory for fast turnaround to in-house technical engineering support,” explains Bob Marshall, Vice President of Engineering and Services.

A case in point is the recent acquisition of Brozelco, Inc., with locations in Rockford, Kingsport, and Chattanooga, Tennessee, known for fabricating operator buildings, e-houses, and electrical enclosures popular with mines and asphalt processing plants. Adding this capability expanded Galco’s portfolio and created new strategic upside alongside the company’s service-driven model. “In 2030, that’s going to be a $5 billion market,” suggests Muldowney.

Ranging across markets
As a result, the company remains agile in a wide range of markets, giving its team of 15 technicians the scope they need to be the best-versed professionals across an impressive range of big-name products in electronics and technology. But market agility is only part of the strategy.

For construction-driven sectors such as data centers, speed and coordination matter as much as product availability. Galco’s model is designed to support build-outs by helping contractors and subcontractors get the right components, controls, and support quickly, often while projects are still in design.

Beyond the company’s focus on expanding its capacity to provide enhanced services in water and motion detection, full motor and pump repair, and support in harsh environments, the team continues collaborating with OEMs that support fabricators. “Being a broad-based distributor means we’re not tied to one market. For instance, if food and beverage takes a hit for whatever reason, we still have those other markets,” Muldowney says.

Having driven phenomenal growth since 2019, when the company employed fewer than 100 people, Sabia’s arrival as CEO was a notable game changer, according to Marshall. “When Allison came aboard, we really changed the trajectory of our company, with more forward focus,” he says. Sabia’s vision helped accelerate acquisition, deepen supplier relationships, and support modernization, including the implementation of a new enterprise resource planning system.

Beyond significant capital investments by parent company Freeman Spogli, Sabia, who comes from a competitive public company background, is clear on what drives the company’s overall success: “90 percent of it depends on the people—and then obviously aspects like inventory and systems and processes. But if you don’t have the right people sailing the ship, it doesn’t matter,” she says.

Today, the company’s leaders describe the growth journey as demanding, but worth the effort. A newer focus area is data center capability. With leadership identifying hundreds of businesses nationwide that can build and equip large-scale facilities, Galco is positioned to support contractors and specialized contributors, including electrical, cabling, HVAC, and controls companies serving this space.

“It’s not always easy to find those companies when the build-out is ongoing, but it’s been an absolutely great business for us in the last six months to a year,” Muldowney says, noting that recently landing a big client in this space has made the hard work worth it. In this sector, the company’s capabilities in chiller and internal air conditioning controls proved to be a surprise advantage.

Because Galco operates across multiple disciplines, long-term projects have produced substantial results. This proved true in Chattanooga last year, where the team supplied and delivered more than $1,000,000 in products on a tight timeline to keep a major project moving.

Ahead of the trends
Staying data-driven and market-aware is central to staying ahead. Galco’s leaders describe a disciplined approach to research and development, including daily market reporting, third-party research, and close collaboration with suppliers who track demand by region and application. Muldowney notes that semiconductor signals can serve as a leading indicator, helping the team anticipate shifts four to six months ahead. The same rigor extends to Galco’s internal data—especially customer purchasing behavior and digital engagement signals captured through the website. By analyzing what customers search for, compare, add to cart, and ultimately purchase (and where they abandon or ask for support), teams can spot emerging demand patterns earlier, refine assortment decisions, and prioritize inventory and content investments where they’ll have the greatest impact. In combination with supplier intelligence, these first-party insights help leadership make faster, more confident decisions about forecasting, merchandising, and go-to-market strategy.

Sabia is clear on how the company defines success. “To be successful in industrial distribution, you need to realize it is not just about volume. It’s about your reach, capability, and relevance to the customer experience,” she says. The throughline is customer outcomes, especially when downtime is on the line and decisions need to move quickly from design to quote to delivery.

By combining deep inventory, technical services, and a rapidly evolving digital experience, Galco is raising expectations for what industrial distribution can deliver. For customers, that means faster answers, smarter support, and the confidence that the right products and expertise will be there when the job is on the line.

The post Where “Going the Extra Mile” Means “Getting Closer to Your Customer”<p class="company">Galco</p> appeared first on Manufacturing In Focus.

Terradyne Armored Vehicles was originally launched in 2011 as a segment of Canadian auto parts giant Magna International. The company, which focused on armored vehicle production from the beginning, was spun off as a standalone entity in 2014, and last year marked its eleventh anniversary as an independent business.

Terradyne offers four main models under its Gurkha line, named after the famously tough soldiers from Nepal who have fought for Great Britain since the 19^th century. These models consist of a light armored patrol vehicle (Gurkha LAPV) which weighs 16,000 pounds (7,258 kilograms) and measures 6,116.9 mm x 2,454.2 mm x 2,645.6 mm; a rapid patrol vehicle (Gurkha RPV) weighing 15,500 pounds (7,031 kilograms) and measuring 6,207.5 mm x 2,454.2 mm x 2,499.2 mm; and a multi-purpose vehicle (Terradyne MPV) weighing 16,500 pounds (7,484 kilograms) and measuring 6,356.8 mm x 2,454.2 mm x 2,633.9 mm.

The company’s fourth model is a civilian limited-edition vehicle (Gurkha CIV) that weighs up to 13,500 pounds (6,123 kilograms) and is 6,207.5 mm long x 2,454.2 mm wide x 2,499.2 mm high.

The biggest change at the company since we last spoke in August 2024 has been the release of “a new variant of an existing model,” shares Sales Manager Lucus Witzke. The new variant represents “a first for Terradyne—an armored vehicle for law enforcement specific to EOD, which stands for Explosive Ordnance Disposal,” he explains.

The MPV FORT (Forward Ordnance Response Team) EOD recently made for the City of Tampa, Florida was a variation of the MPV for law enforcement, and will be used by a police bomb squad, Witzke says. The purchase was part of a two-vehicle deal, with the other being a standard law enforcement model. “We have delivered it and are now marketing it to other law enforcement agencies,” he says.

In addition to the FORT EOD, Terradyne has also tweaked another model to create a tactical emergency medical services (TEMS) vehicle which is “basically an armored ambulance,” Witzke says. The TEMS vehicle is also being marketed to law enforcement clients.

These models are built on Ford F-550 Super Duty truck frames and are fitted with a 10-speed automatic transmission, 4×4 shift on the fly, and V8 turbo diesel engines. “We use the Ford F-550 chassis for all Gurkha models, so we are limited to what direction Ford goes in. From what I’ve heard… for the Super Duty lineup, there are no electric or hybrid engines in the forecast,” Witzke says. Fuel capacity for all four models is 40 gallons (151 litres), and each model is equipped with a four-wheel vented disc anti-lock braking system.

All models save the CIV feature armor plating (with the armoring available as an option on the civilian model as well). The CIV is the only Terradyne vehicle that is available to the public at present. This is a brawny, dark machine that would definitely make an impression on city streets.

Witzke cites the materials that go into the company’s vehicles and its customer support as Terradyne’s points of difference in the market. Technical specifications state that armor plating on the LAPV, MPV, and RPV warrants a B7/STANAG 2 rating, a military standard set by the North Atlantic Treaty Organization (NATO). And Gurkha vehicles are subjected to intensive third-party testing involving live ammunition and explosive blasts.

Terradyne does not claim its vehicles are completely bullet- and bomb-proof, but simply well-protected against such threats. Plating on the LAPV, MPV, and RPV is fairly light as far as armor goes, and in addition to being well-fortified, Gurkha vehicles are relatively quick, which is an important factor when conducting police raids or rescuing wounded soldiers under fire. The wheels on Gurkha vehicles feature special inserts that keep the tires in workable condition even after they have been punctured by bullets or shrapnel, while the windshield glass is also tough and resilient in the face of gunfire.

In addition to producing top-of-the-line machines, Terradyne works hard to serve its clients. The company maintains a steady supply of spare parts and tires and can manufacture replacement components upon request. It is receptive to customer feedback and can customize its basic product line, as evidenced by the FORT EOD vehicle. “Something we’ve learned over the years is our customer service apparently is next-level compared to our competitors, so that has given us an advantage,” notes Witzke.

Design and manufacturing duties are handled in-house, with Terradyne employing roughly 50 people and producing around 100 vehicles each year. Each armored car takes between 20 and 24 weeks to complete—which seems a long time until you consider the standards each vehicle needs to meet. Not every truck on the road is designed to withstand a barrage of bullets or a grenade attack.

Gurkha vehicles are sold either through dealers or direct to customers, and the company’s most popular vehicle varies from year to year. For 2025, the MPV proved to be the most in-demand model, says Witzke.

Certainly, Terradyne takes pride in all its high-quality vehicles and holds both ISO 9000 and 14000 certification. It is also registered with the Controlled Goods Program, an initiative run by the Canadian government. Thanks to this registration, Terradyne is authorized to export its military-style vehicles.

Back in Canada, Terradyne is among a handful of qualified potential suppliers for a Canadian Armed Forces light utility vehicle (LUV) replacement initiative. Ottawa intends to spend up to $1 billion on a new “protected, lightweight, multi-role, and highly-mobile ground wheeled vehicle,” states the website of the Canadian Defence Review, a military journal.

Between 2,000 and 2,200 replacement vehicles are needed in total, “with up to four variants: command and reconnaissance vehicle; utility vehicle; military police vehicle; and cable-laying vehicle,” says the journal. The program also involves “ancillary equipment, integrated logistics support (ILS), and an in-service support solution.”

To be sure, Terradyne has a good shot at winning work with the LUV program, due in part to the amount of Canadian content that goes into its Gurkha line, says Witzke.

The company is also excited to be participating in the World Defense Show in Riyadh, Saudi Arabia in early 2026. This will be the first time Terradyne has attended this event. “There are a lot of Terradyne vehicles operating in the Middle East as of today,” Witzke says. “Other opportunities might be there. Our end-goal is to expand our presence from what we already have there.”

When it comes to promotion, the company relies heavily on trade shows to highlight its products. “We’re very particular,” says Witzke. “We do some print advertising with law enforcement in the U.S. and Canada, but a lot of [our promotional efforts] are trade shows. We find it’s a lot more effective to physically get a vehicle in front of somebody, as opposed to sending pictures.”

As for challenges, he cites tariffs and “increased prices in the supply chains.” The most consistent challenge, however, is simply the nature of the armored car business. “The sales cycle is very long; it’s a big-ticket item. There are a lot of hurdles that need to be overcome in that process.”

Going forward, Terradyne wants to stay in Newmarket and produce more armored cars from its core lineup in addition to interesting variants, such as the FORT EOD and TEMS vehicles. Witzke anticipates “further expansion of our footprint in key areas: Canada, the United States, Europe, and the Middle East,” while the company continues to hone its expertise.

In the early days, “we were the new kids on the block that nobody had ever heard of,” he says, adding that the client base “is a very tight-knit group, especially in law enforcement. They talk with each other and share reviews of what equipment is good. It takes a very long time to develop a reputation.” Terradyne Armored Vehicles is well on its way.

The post Specialty Vehicles for Specialized Situations<p class="company">Terradyne Armored Vehicles</p> appeared first on Manufacturing In Focus.