In an address to The Vernier Society last year, Ai Group CEO Innes Willox highlighted advanced manufacturing’s importance to Australia’s future prospects, and the need to inspire companies that may be seen as ‘traditional’ manufacturers to become ‘advanced’.

Based in Highett, Victoria, Ronson Gears was established in 1954 by Melbourne engineer Ron New. Ronson’s current Managing Director – Gordon New – commenced his career as a cadet at Robert Bosch Australia before a stint working and travelling in Germany and Europe. A mechanical engineer, he returned to Australia and joined the family business in 1976. Today the company manufactures gears, associated power transmission components and proprietary gearbox assemblies for a range of customers and industries.

Ronson could be regarded as a ‘traditional’ manufacturer, as gears themselves are indeed a ‘traditional’ mechanical component. Dating back to hundreds of years BC, gears are among the oldest equipment known to mankind. Originally carved by hand, the first mechanical machines built specifically to cut more accurate gear profiles date back to the 19th Century, when English inventor Joseph Whitworth patented the first gear hobbing process in 1835. So how do businesses like Ronson transition from such deep ‘traditional’ roots to become a truly ‘advanced’ manufacturer?

In Willox’s address, entitled ‘The future of Australian manufacturing: ‘traditional’ or ‘advanced’ … or both?’, he outlined the criteria that define an advanced manufacturer:

  • High value-add: Servicing niche markets, often with highly customised product and service offerings.
  • Knowledge intensity: Characterised by sophisticated design, extensive IP, automated processes, and digitally enabled businesses and supply chains.
  • Investment in the workforce: Including close engagement with staff.
  • Innovative: Investment in research & development, readiness to add new products and services, responsiveness to changing opportunities, and the ability to evolve business models.
  • Global outlook and global opportunities: Scanning the horizon, engagement in and with supply chains, global servicing, investment opportunities abroad.

Ronson Gears has developed to meet this definition in the following ways:

  • High added value: Gear manufacturing is a highly specialised niche industry. With demand for accurate, high-quality products continually increasing, Ronson’s service offering has met the challenge by continually investing in state-of-the-art technology. Millions of dollars have been invested in recent years in rigid, fast, accurate CNC gear-hobbing machines, advanced CNC gear-grinding machines and CNC analytical gear metrology equipment. Ronson’s enhanced capability now extends to the manufacture of master gears.
  • Knowledge intensity: Ronson’s operating systems have recently been upgraded to enable it to implement Industry 4.0, incorporating automation and robotics.
  • Unique processes and continual development of manufacturing IP: Ronson’s sophisticated ERP system controls all aspects of business operations; interconnected to the company’s quality management systems, it conforms to ISO 9001:2015 and AS 9100:2016 standards,.
  • Investment in workforce: Apprentices are retained annually at Ronson Gears, and with no gear-manufacturing courses conducted in Australia, external engineering training is enhanced by in-house training in gear-cutting and gear-grinding. This extends to all employees for various aspects of manufacturing, with some overseas travel for specialised training, and attendance at gear industry seminars and exhibitions. Ronson also supports engineering students at local universities by providing guest lectures, internships, and assisting with course-based projects.
  • Innovation: Ronson introduced Lean processes and methodology some years ago, while innovative application of tooling concepts and tooling technology are reducing process cycle times by up to 80% over traditional methods. New manufacturing techniques are continually being developed to assist customers with product development and requirements.
  • Global outlook and opportunities: Since 1993 Ronson staff have travelled the world to stay abreast of industry developments. Membership of the American Gear Manufacturers Association (AGMA) and Eurotrans, Europe’s committee of gear associations, has enhanced the company’s reputation and creditability. Gordon New has sat on the board of AGMA and addressed international meetings and conferences in many countries. The company partakes in trade missions, both local and international, organised by industry and government. Such connectivity and exposure have resulted in Ronson exporting product to blue-chip companies globally and enabled connection to the defence and aerospace industries.

Ronson’s transition to advanced manufacturing has been gradual, requiring foresight, courage and investment, but has resulted in the company becoming a truly globally competitive gear manufacturer while also providing Australian industry with locally sourced precision gear product. At every new stage of the journey, Ronson’s knowledge and IP has expanded, with corresponding increases in moral and excitement within its ranks.

Industries now served include mining, defence, construction, rail, commercial aircraft and space. Blue-chip customers that put their trust in Ronson include Siemens, Caterpillar, BAE Systems, Marand Engineering, Dormakaba, Lockheed Martin, Sandvik Mining and Downer.

According to Gordon New, without having transitioned to advanced manufacturing, Ronson would not have such a clientele. Indeed, the company may not even exist!

www.ronsongears.com.au