Gear shift

Managing director, Reece Garrod, has included in his vision, a continuous investment plan that included AS9100 approval and enhancements in software technology to encompass manufacturing processes, quotation preparation, production scheduling, corrective action reporting and production part approval processes (PPAPs).

Gibbs Gears became AS9100 approved in March 2010 and is accredited by LRQA to serve the aviation industry. As a specialist gear manufacturer however its customer base spans a number of additional market sectors and the company maintains some 50 gear cutting machines to meet its customers' requirements.

The strategic investments in technology began with the retrofitting of standard hobbing machines to full CNC versions. Since moving to Stoke Mandeville, Gibbs Gears has introduced two further Reishauer gear grinding machines – taking the total to three, two 1010 XYZ CNC milling machines with 4-axis capability, a CNC milling cell and a new Jones & Shipman CNC Ultramat 1000 to strengthen grinding capacity. In addition, the company's first Lorenz shaping machine has been purchased predominantly with aerospace contracts in mind, but it is also being put to effective use with other work. The plan is to continue the current investment programme over the next 18 months to modernise the whole manufacturing cell.

Last year's machinery investments also included the introduction of Gibbs' first sliding head turning centre as a direct result of a long term contract with a key customer. Citizen was asked to supply a machine to incorporate a hobbing facility which allows the rapid, lights out manufacturing of large batches of planet gears of small diameters and pitches. This was augmented with the installation of a Phauter Gleason P60 with auto feed.

For 2011, Gibbs Gears has started negotiations with Phauter Gleason for a new P90 Hobbing Machine which will complement its existing P60 machine.

Although not a new investment, a Wenzel LH54 CMM with dedicated gear checking software facilitates high levels of accuracy and precision whether to BS, DIN, ISO, ANSI or AGMA standards.
The software infrastructure has also seen investment with the incorporation of Tricorn's MRP and Seiki Systems' scheduling software which allows customers to receive up to date order progress information. Daily production reports are used to highlight bottlenecks and ensure efficient throughput at all stages of the manufacturing process.
In terms of current news, Gibbs Gears has announced a worldwide exclusivity agreement with WheelTug. “We have been working with this customer on a particular project for some time now,” explains sales manager, Phillip Maurice. “The project has broken new ground for us because we've been heavily involved at the design stage – something we're not widely known for.

“A Gibbs Gears gearbox will be attached to an American motor for trials to be completed by Spring 2011 and this represents a great opportunity towards fulfilling our ambitions of becoming a centre of excellence in the design, development and production of gears and transmission components.” Other recent highlights included the recruitment of new apprentices.

Mr Maurice concludes: “We will be exhibiting at the forthcoming Autosport Exhibition at the NEC Birmingham in January 2011. We'd be delighted to welcome new and existing customers onto our stand to discuss their manufacturing requirements.”

Gibbs Gears
www.gibbsgears.com