Rexnord Stearns

Source: Manufacturing Digital

Date :4/11/2008 3:55:48 AM

Stearns Division is the largest supplier of spring-set electrically-released brakes in North America. With many years of brake design and manufacturing experience, Stearns has built a reputation for being responsive, innovative and reliable

Written by Ian Armitage and Produced by Pat Harlow

Cudahy, WI. based Stearns is part of Rexnord Industries’ Special Components division, very much a market leader on its own merits, and driven by manufacturing best practice. Exec recently spoke with director of manufacturing and engineering David Warnke, who told us more about the employer of more than 160 people.

“Stearns manufactures a comprehensive line of standard and special AC and DC industrial brakes and clutches,” says Mr. Warnke, who has been a vital cog in the Stearns engine since joining the team in 1994. “It was the first company to develop self-adjusting brakes, and it pioneered brakes for hazardous locations as well as the first electric motor clutch.”

Founded in 1916, Stearns invented the first DC clutch and brake in 1928 and originated the AC motor brake in 1935. Some of its 40-year-old units are still in operation.

Self-sufficient

Within its 100,000 square foot facility, Stearns, which became part of Apollo Management LP in 2006, is almost completely self-sufficient. It has its own CNC/DNC machine shop and manufactures its own brake friction discs and clutches that are typically fitted to the non-drive end of electric motors and supplied to such major US manufacturers as General Electric. It also has complete assembly capability, an electronics manufacturing capability and an R&D lab, where it builds prototypes and conducts product reliability testing.

As a result, Stearns is totally focused on the needs of its customers setting, what Mr. Warnke calls “the standard for brake and clutch quality and on-time performance”. Internal Six Sigma and Demand Flow Manufacturing Programs continue to support Stearns’ goal of quality products with reduced cycle times.

As if that isn’t enough, with a factory-trained sales force, knowledgeable CSR’s, worldwide distribution and complete EDI capabilities, Stearns can respond to all customer needs.

“Our focus on the customer is what truly differentiates us from the competition,” says Mr. Warnke. “Our customer service is unrivalled.” Its people, equipment and systems are all geared to produce results.

Necessary change

Stearns hasn’t always been so focused; in fact, the story was once very different. Indeed, around eight years ago, says Mr. Warnke, it was decided to completely reorganize the manufacturing operation in order to better serve customers. “We were shipping only about 80 percent of the product by the date the customer wanted it. We knew we had to do something different, so we split the product lines in the factory into two groups.”

The two groups – a Solenoid Actuated Brake (SAB) Team and an Armature Actuated Brake (AAB) Team - were also trained, according to Mr. Warnke, to help them function as a team. The teams were also encouraged to put one target - the “customer want” date - above everything else.

Although it took a while before the two groups evolved into proactive teams, once they got used to the new way of thinking, the results were outstanding. Indeed, today, on-time delivery from the plant has reached a consistent 99.7 percent – remarkable!

According to Mr. Warnke, it may not be possible to better that, but he knows Stearns can’t sit on its successes. “We have been very successful and will continue to be – that will never stop. For instance, to achieve this, we try to run two kaizens at once, one ‘transactional’ and one on the production floor.” This is designed to continue the remarkable improvement.

Electronic kanban

As part of the development process, Stearns also created an electronic kanban system, which is linked to the factory and the vendors, and runs on Stearns’s Cincom manufacturing software.

The implications of this are extraordinary and mean that when a part reaches a certain level, an order is opened automatically. If it’s a manufactured part, the software automatically creates a routing for the factory to make more; if it’s a purchased part, the order is automatically faxed to the supplier.

Today, the process has been automated as far as it can be, so that all the machined castings, electrical coils, and other components produced on-site are made to order, not to forecast, and the whole supply chain works on a pull basis.

Is AAB the future?

Stearns Division is today the largest supplier of spring-set electrically-released brakes in North America. It remains committed to exceeding customer expectations, and is able to more thoroughly understand their needs.

But, what of the future? Well, other than continuing to improve processes and maintain strong customer ties, Mr. Warnke believes the current trends are “leaning towards the AAB product,” with inquiries coming from a number of industries. Wind power is a great example of this and Stearns is positioning itself in that developing market.

“We are moving into the wind power industry and we have one large customer. That customer has three blades on their windmill and has to control the pitch of their blades. There is a motor and a brake on each blade so they can change the pitch of the blade and hold it in that position, which our brake does for them. That is becoming a booming business for us.”

Wind power is being heavily promoted in the US and worldwide as businesses become increasingly environmentally aware. Undoubtedly though, other opportunities will also present themselves.

Click here to view the corporate brochure on Rexnord Stearns