A no longer available component was about to take down a critical machine. We reverse engineered it, machined a replacement to spec, and the line never stopped. We maintained production of the reverse engineered part to fulfil monthly orders of the same component, ensuring the line doesn’t go down again.
Service: Reverse engineering · Precision CNC machining
A consumer packaged goods manufacturer was running a production line built around an older piece of large equipment that still ran well, but depended on a precision machined component that had quietly become a single point of failure. The part was worn and near the end of its life. The original equipment manufacturer no longer supported the machine, the component was no longer available from any supplier, and they were completely out of their last 100ea order from the overseas OEM with no drawing on file. The only reference that existed anywhere was the worn part still in the machine.
If it failed before a replacement was sourced, the line would stop lost throughput, missed shipments, and emergency sourcing. Replacing the whole machine was a high six figure project that solved a problem the customer didn't have. The machine was fine. It just needed one good part.
Reverse engineer the existing part. With no drawing available, we captured the worn part's full geometry, distinguishing the as designed dimensions from the wear it had accumulated, then produced a complete, dimensioned engineering drawing. That drawing became a durable asset that can be used to create a stead supply of this and other parts like it via monthly orders.
Machine the replacement to spec. We moved the part into production on our CNC equipment, machined it to the tight tolerances the application demanded, and inspected it against the new drawing before it left the shop. We then asked the customer to test the new part.
Deliver before the line went down. The replacement was installed ahead of the failure they were bracing for, and the machine went back into normal service. No line down, no expensive machine replacement, no scramble.
Facing the same problem? If you're running well-maintained equipment that's outliving its parts supply, you don't need a new machine. You need someone who can recreate the part, accurately, to spec, and fast enough to matter.
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Please note: These customer names are intentionally withheld due to nondisclosure and confidentiality agreements. Please contact us if you would like to discuss any of these past client projects.