Geared up for Change

**This story first appeared in the October 2025 edition of AMT Magazine**

Being faced with growing global demand for the high-precision gears that Ronson Gears produces is the sort of problem that might put a spring in the step of any company director. But for Ronson Gears technical director Jason Graham, the primary issue was throughput, as the company sought to serve a highly competitive global market.

“We had a large backlog of work. Our equipment just wasn’t technologically advanced enough for what we were doing. Setups were taking far too long,” he says.

Founded in 1954 as a local operation in Victoria, Ronson Gears today has become a globally trusted manufacturer, delivering high-precision gear solutions for industries ranging from outer space to mining.

Offering full-service manufacturing capabilities covering turning, milling, gear cutting, grinding and advanced measurement, Ronson Gears employs 46 people and operates 24 hours a day, six days a week across three shifts.

Graham says the company needed a solution that could integrate seamlessly into its operations while maximising uptime and capacity – minimising manual intervention and allowing continuous, flexible production. To pursue this, Graham headed to Hannover for major production technology trade fair EMO 2023 to inspect a variety of advanced machining technology.

“Initially, I was considering a more basic 3+1 axis twinpallet machine — I hadn’t planned on exploring a multipallet system,” he says. “But during my EMO visit, I came across some and was genuinely impressed.”

On his return to Australia, Graham says he was drawn to a horizontal 5-axis Makino a500Z with a 14-pallet system – and began negotiating with local distributor Headland Technology.

“The machine wasn’t the cheapest on the market, and I’ll admit I haggled quite a bit with Headland’s sales representative, Craig, but ultimately, the technical capability and build quality of the Makino sold me. I knew it was the right solution for us.”

Makino says the machine builds on its existing nx-series four axis horizontal machining centres, but with the addition of its factory built “Z-type” fourth/fifth axis combination to accommodate more complex part geometry challenges in a minimum number of workholding setups and machining operations.

The a500Z is built to minimise force path lengths both through the spindle as well as through the workpiece, efficiently transferring both cutting loads and reactive forces into the machine’s three point levelled bed – a move that maximises both metal removal rates and perishable tool life due to its system rigidity.

Graham says that while he considered other machines, the Makino’s technical specifications and build quality were what impressed him.

“I thought Makino was out of reach for us… but after working with Craig from Headland, the numbers made sense. It wasn’t the cheapest option, but we realised it would pay off in the long run.”

The decision to invest in the Makino a500Z with a 14-pallet pool was based on productivity gains, risk minimisation, and the ability to grow their business into new markets with more reliable technology.

Since the machine was installed on-site, Graham says it quickly integrated into Ronson’s operational rhythm. “We saw immediate benefits. Jobs that used to take 10 hours for setup now run with virtually no lost time. It’s a game-changer in terms of flexibility and planning,” he says.

Its ease of use and automation reduced downtime and enabled quicker responses to production changes, he adds.

The pallet pool system enables easy prioritisation of urgent jobs, and even with full-time operation, the machine still has capacity for more work through staffing adjustments.

Graham says he’s also noticed a lot of operator enthusiasm:

“There’s been a lot of excitement about the machine; it’s a joy to use,” Jason added. “We have the space and now the capability. The next challenge is hiring more of the right people, which many in manufacturing are struggling with right now.”

The company continues to work with the team at Headland Technology, with Graham saying the strong aftersales support they offer reinforced their decision to go with the Makino.

“Service and support are vital. With Headland, I can always get someone on the phone—unlike other suppliers

where we’ve struggled. That quick response makes all the difference,” Graham says.

“It’s a great machine and the service and installation from Headland were first-class. Excellent partnership.”

He adds that while the investment was a steep one, his advice to other manufacturers is that the rewards have been worth it.

“Stretch your budget if you can. Investing in quality pays back in performance and reliability. My mentor always said, ‘Buy the best you can afford, and it will reward you over time.”