page 1
page 2
page 3
page 4
page 5
page 6
page 7
page 8
page 9
page 10
page 11
page 12
page 13
page 14
page 15
page 16
page 17
page 18
page 19
page 20
page 21
page 22
page 23
page 24
page 25
page 26
page 27
page 28
page 29
page 30
page 31
page 32
page 33
page 34
page 35
page 36
page 37
page 38
page 39
page 40
page 41
page 42
page 43
page 44
page 45
page 46
page 47
page 48
page 49
page 50
page 51
page 52
page 53
page 54
page 55
page 56
page 57
page 58
page 59
page 60
page 61
page 62
page 63
page 64
page 65
page 66
page 67
page 68
page 69
page 70
page 71
page 72
page 73
page 74
page 75
page 76
page 77
page 78
page 79
page 80
page 81
page 82
page 83
page 84
page 85
page 86
page 87
page 88
page 89
page 90
page 91
page 92
page 93
page 94
page 95
page 96
page 97
page 98
page 99
page 100
page 101
page 102
page 103
page 104
page 105
page 106
page 107
page 108
page 109
page 110
page 111
page 112
page 113
page 114
page 115
page 116

January 08 www.bus-ex.com 79 In the business of industrial gear repair and manufacturing, the key to success is experienced employees who are willing to take on all sorts of challenges, general manager Randy Burdick explains to Gary Toushek FalkRenewPragerGear Topgear

80 www.bus-ex.com Janurary 08 The Prager part of Falk Renew began as a family owned machine shop business in New Orleans, Louisiana in 1897. It moved into making gears as a necessity for repairing gear boxes made by others. In the 1970s Prager was the first gear company in the southeast to invest in gear grinding technology, which catapulted it into the high speed gear repair business. “It was a big deal for a business its size to have this kind of technology at the time,” says general manager Randy Burdick, “and Prager established itself as a fast, reliable alternative for OEM supplied gear reducers, that had the ability to reverse engineer all types of gearing.” In Falk Renew Prager’s case, says Burdick, “reverse engineering is looking at the engineering principles of a part that Falk Renew Prager did not design/manufacture and attempt to make it better by applying sound engineering principles that incorporate strength and material, heat treat and manufacturing advancements.” Customers often bring in gear boxes that can be 20 or 40 years old and are considered obsolete by the original manufacturer, and request a mechanical upgrade. Falk Renew Prager’s ability to increase the power density of a customer’s existing equipment is derived by employing the latest technology in terms of metallurgy and manufacturing processes, with its in house reverse engineering expertise. The end result is a highly engineered design solution that will provide reliability to the customer and can be delivered fast. Falk Renew Prager is owned by Milwaukee, Wisconsin-based Rexnord Industries, Inc. (a manufacturer of highly engineered mechanical power transmission components, drives, and conveying equipment, with 5,000+ employees at more than 30 manufacturing facilities), which acquired the Falk Corporation in 2005. Falk Renew’s repair processes and Rexnord’s RBS daily management system were implemented to create a lean facility, says Burdick, and “business has exploded.” As well as its solid customer base along the Gulf coast and southeast, Falk Renew Prager serves a large part of the industrial gear repair market in Venezuela, as well as parts of Mexico and the Caribbean, in several industries—pulp & paper, petroleum, mining, power generation, material handling, sugar refining, chemical processing, and steel mills. “Most repair facilities attach themselves to a certain market segment,” says Burdick. “Falk Renew Prager can manufacture gearing products for a wide variety of applications regardless of industry. The ability to manufacture through-hardened as well as casehardened and ground gearing puts Falk Renew Prager in a unique position in the repair market place by providing a single source option to our customers for repairs.” Falk Renew Prager’s business has three facets, the first being gear manufacturing, the second being repair and the last being field service, where skilled technicians are deployed with the appropriate equipment to trouble shoot and/or make repairs on a customer’s site. One reason business is booming for Falk is that the gear manufacturing market in the US has been shrinking over the decades, due to consolidations, acquisitions, and bankruptcies. Consequently, customers have been importing OEM gear boxes from companies in Europe, Asia and elsewhere, while American gear box companies have become more service oriented. It means that when those boxes need repair, there are no spare parts easily obtainable, so it’s been left to the American companies to do the repairs, and make replacement gears. “That’s how Prager got its foothold in this niche, and has done well developing the service aspect of its business over the years.” Technology is changing in the gear business; “The ability to manufacture throughhardened as well as case-hardened and ground gearing puts Falk Renew Prager in a unique position in the repair market place by providing a single source option to our customers for repairs”