Capabilities
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Process Gear specialises in manufacturing gears, shafts, and splines for heavy industrial and specialty uses. Essentially, we take our customer’s prints and engineer a quality process to manufacture the required part. We focus on building controlled and efficient processes with quality built-in. We do prototyping and production work and handle all the logistics for our customer from raw material to the end product that they require from us.
We have the capability to manufacture parts either from bar stock or forgings. The American Gear and Manufacturers Association (AGMA) has a nationally accepted classification system for gear manufacturing ranging from a low of one to a high of 15. Process Gear’s business mix runs from the mid-point towards the high end of this range.
Our 42,000 sq ft facility in Schiller Park is structured in the following manner:
1. CNC Turning and Machining: We have the capability to produce blanks in-house, whether we choose to out-source globally or not. Currently, we have 9 CNC turning machines (e.g., Daewoo, Doosan, Mazak, Hardinge, Femco). We have dual spindle capability on some of these machines. We also have 2 CNC machine centres (Haas) as well as other peripheral drilling/tapping equipment. We are planning to replace some of the older equipment in our CNC turning department over 2007 and 2008.
2. Gear Cutting: This area is the core of our operations where we have CNC 6-axis hobbing equipment. In particular, we have 3 CNC gear hobbers (Gleason, Mitsubishi) as well as 5-6 manual pieces of equipment (Koepfer, Liebherr, Barber Coleman). We recently purchased a brand new Gleason Gear Hobbing machine which has extended our capabilities on the pitch range of gears that we are able to manufacture. We also have 4 CNC shaping machines (Lorenz, Fellowes).
3. Gear Grinding: We have set up a separate climate controlled area for all our gear grinding work. In 2005 we bolstered this department through the purchase of a Hofler Gear Grinder. Combined with our Reishauer gear grinders and other CNC grinding capabilities, we can achieve a production level up to AGMA Class 14. We currently do not have any ID grinding capability but manage several vendors who can do this work for us.
4. Speciality Operations: Our in-house capabilities also including shaving, honing, thread grinding, glass beading, deburring and stamping.
5. Quality Assurance: We have rigorous inspection criteria which are applied throughout the manufacturing process until final inspection. Our motto is that quality has to be built into the process. Our state of the art inspection equipment including a vision system and an M&M gear analyser help us to achieve and maintain these high standards.
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