If You Want To Go From Outsourced To In-House Machining, Read This
GEN-Y Hitch has a winning template and an awesome origin story.
Carl Borkholder didn’t plan on being in machining, but sometimes life throws a hitch at you. It all started when his tree cutting service had multiple trailers that needed different connections.
There wasn’t an easy one-size-fits-all solution, so Carl went to work. He designed one hitch system for any trailer you back up to. He cut and welded everything himself and got it to work, and before long his crews and his friends were equipped with the invention.
Soon after, he got a patent for it and started building them out of his garage. In 2012, he got out of tree cutting and founded GEN-Y Hitch. Their goal: to be the only hitch you’ll ever need.
From Outsourcing to In-Housing, with Help from Ellison
GEN-Y had an innovative product from the start, but for the first handful of years, they didn’t have full control of the process. “Up until 2018 when I joined GEN-Y, everything was outsourced,” said Dan Miller, President & CEO. “At that point, we decided to bring in a few pieces of equipment to vertically integrate our manufacturing.”
“It was an ambitious change, and the key to making it successful was hiring the right people and trusting them. We have an amazing team here, all of whom are service-driven and caring. We also trust and respect Ellison, and I know they do the same. That creates a win-win.”
The growth has been stunning. When Miller signed on in 2018, GEN-Y had about five people on staff. As of mid-2023, that headcount had ballooned to over 60 people.
First Machine Installed: The DNM 5700 Vertical Machining Center
When they decided to move to in-house machining, GEN-Y did its due diligence. Haas, Okuma, and DN Solutions (formerly Doosan Machine Tools) were all evaluated. In the end, they went with DN and Ellison Technologies because of the obvious truth: the same capabilities at a much better purchase price.
What was a single DNM 5700 quickly multiplied into four of them, three of which are equipped with automatic part loaders. “The DNMs handle surfacing, holes, edge machining, and finish machining on our adjustable drop hitches,” Miller said.
Next Up: The PUMA TT
With the success of the DNM machines, GEN-Y suddenly had a narrowed list of one OEM for their next project. They wanted the ability to make a certain part and run lights out, and they brought the challenge directly to Nick Muegge, Sales Engineer at Ellison Technologies.
“We wanted to make Torsion inner bars and ball mounts, as well as other intricate parts on the new turning center,” Miller said. “Nick presented us with the PUMA TT and we went with it. Bought the first, loved it, and bought a second one.”
“We’re now running both machines two full shifts per day. Both of them have bar feeders, and one has a Doosan Robotics Cobot from Ellison for specifically loading and unloading a dual ball hitch. It doesn’t complain. Just shows up every day and gets to work. It’s been a great fit.”
The Final Piece (For Now): The NHP 4000 Horizontal Machining Center
In early 2022, an NHP 4000 from DN Solutions joined the GEN-Y team. The NHP makes link arms for torsion products and shank material. The initial promise that it would reduce operator involvement time has come to fruition.
“We went with Nick’s recommendation to go horizontal to improve efficiency,” Miller said. “It’s been an exciting, robust machine. The pallet changers and automatic clamping in particular are remarkably efficient.”
The big difference between GEN-Y’s DNMs and this NHP is the clamping system. Verticals use manual clamping, but the horizontal features hydraulic fixtures. Ellison recommended the ideal tombstones and clamping systems based on the various parts GEN-Y would machine. After that, it was off to the races.
The Ellison Way Might Just Be Your Way, Too
From the start, the team at Ellison felt comfortable with the GEN-Y team, and the feeling was mutual. That’s a great beginning to a relationship, but consistent work has to be put in to grow the relationship over time. That’s been Miller’s experience.
“Ellison mirrors how we run our business and support our customers,” he said. “If we have an issue or present a challenging part, they provide the best solution. Plus, they’re so responsive. We can feel the urgency they have to take care of us and to make sure we’re in a position to succeed.”
If that sounds like music to your ears, feel free to talk to Ellison anytime about bringing your machining in-house. There’s a good chance that you won’t find a better combination of high-value machinery and high-value support, no matter how far and wide you look.
