EBM LAUDED FOR EXCEPTIONAL PRODUCTIVITY

Eagle Bridge Machine & Tool Inc.’s exceptional strategy to increase its efficiency and productivity within the restraints of a slowed economy is the featured cover story in a recent issue of American Machinist Magazine. Founded in 1877, American Machinist is the premier journal of the American metalworking industry.

“In three short years, [EBM] has transitioned from a 60-man jobshop running three manned shifts to a 30-man jobshop running one manned shift and one completely unmanned,” writes Patricia L Smith, in American Machinist. “The company has also gone from 23 machine tools to 12. At the same time, it has increased capacity 40% and locked in a six-year contract to make train parts for its largest customer. According to Robert Farrara, EBM's president, moving from circa-1984 vertical and horizontal machining centers and lathes to fully automated cells has allowed the company to survive -- and even thrive -- in today's rough economic climate.”

The Acela locomotive sports components machined by
Eagle Bridge Machine & Tool, Inc.
(Photo courtesy of Amtrak)

Company President Robert Farrara credits their success largely to the purchase three years ago of two automated CNC systems, manufactured by Toyoda Machinery USA. These machines have the flexibility needed for EBM's main work -- machining castings for mass transit. Among the parts EBM makes are components for commuter railroad cars for the New York Metropolitan Transportation Authority, Long Island Railroad, and Metro North Railroad. It also machines parts for Amtrak's Acela high-speed rail cars.

Like many American shops, EBM lost some lucrative contracts when manufacturing work moved offshore to China. EBM, however, predicted these changes and positioned itself to tackle a huge contract with the mass-transit industry. "Trains are a niche business, and we have a reputation for tackling complicated castings," says Farrara. "We wouldn't be here today without these machines," he asserts.

Another huge change for EBM was moving to an unmanned shift at night. Operators load the automated machining cells, start a computer program, and go home. The machines are all wired for automatic coolant fill and automatic shutoff. An auto dialer is also wired to alert someone at an off-site location if any problems arise.

Leaving for the night with production continuing on the Toyodas was strange, as Tony Farrara, EBM production manager recollects. "As we walked to the door that first night, all was dark, and you could hear the cell running. We came back and stood by it for a while. We knew we had to go sometime, but it didn't seem right -- we were all used to standing by our machines, listening to them running." He admits, though, that their concerns have faded as the Toyodas continue to produce without any major problems. Now, they leave at the end of the day without hesitation.

According to Robert Farrara, all these changes have been an investment in the future of EBM, and he's willing to invest where it's warranted. "I look at it this way -- next year, I'll be getting more sales because I'm more competitive. We go up every avenue to maintain our costs. We won't raise our prices based on inefficiencies."

EBM EMPLOYEES CALLED TO ACTIVE DUTY
WITH ARMY NATIONAL GUARD

Thomas Heaney, left and Chris Warnke

November, 2004

Employees at Eagle Bridge Machine & Tool extended an emotional farewell to two of their colleagues who have been called to active duty with the Vermont Army National Guard.

Thomas Heaney, 41, and John “Chris” Warnke, 34, both of Cambridge, were notified last month that their unit will be deployed overseas, and that they were to report for duty this week. Neither has officially been told where they will be located, only that they will serve as guards for military bases.

Warnke leaves behind a wife and three children ages 10, 8 and 7. He has previously served two years in the Army and the past six years in the National Guard. He was called to active duty during Desert Storm. “I’m very sad to be leaving my family,” he said. “But I’m also very excited.”

Heaney said his family is concerned for his safety. “They are worried if we will come home safely in one piece,” he said.
National Guard service requires one weekend per month and two weeks per year training. Members can be called to active duty once every five years for up to 18 months.

“EBM has been real supportive of us,” said Heaney, who has worked for the machine shop for 21 years. EBM specializes in the production of precision-tooled parts for the international railroad manufacturing industry.

Warnke has been with EBM for about 18 months, he said, and agreed that he has felt a very tight community spirit among his colleagues. “We will miss our families, our friends, and everyone that we work with here at EBM,” he said.

NY STATE SENATOR ELIZABETH LITTLE
TOURS EBM PLANT

Eagle Bridge Machine & Tool, Inc. (EBM) hosted a tour of its Eagle Bridge, NY manufacturing plant recently for State Senator Elizabeth O'Connor Little, who represents the senate’s 45th district counties of Clinton, Essex, Franklin, Hamilton, Warren and Washington. EBM specializes in machined parts for the international mass transit industry.

EBM President Ray Farrara explains to Sen. Little how EBM's new tate-of-the art technology has increased the company's efficiency.

Also touring the EBM plant was Robert E. Furniss, Vice President for North American Business Development for Bombardier Transportation, a multi-national manufacturer of mass transit systems with a plant in Plattsburgh, NY. Bombardier contracts with EBM to manufacture parts for its transit systems, including commuter railroad and subway cars for the New York Metropolitan Transportation Authority, Long Island Railroad and Metro North Railroad, and for Amtrak's Acela high-speed rail cars.

“What EBM does makes Bombardier successful,” said Furniss. “EBM offers high quality products, on-time delivery, and competitive pricing. And that impacts a whole network of secondary suppliers throughout New York State.”

“It’s all about the technology,” said Furniss. “EBM is helping us supply the subway cars that make New York City work. Contracting with New York State companies is our priority,” he said. “Bombardier is committed to the New York State market and to New York-based companies.”

Sen. Little said she will do everything she can to help New York manufacturers remain competitive. “Manufacturing jobs have a tremendous impact on our local economy,” she said. “The businesses we have in New York are our best selling feature to attract more new businesses. They must be on the forefront of new research to create good jobs for our residents.”

Farrara sees Sen. Little’s visit to EBM as a significant opportunity for the company. “It’s great having her here, asking how she can help us,” he said.

“She’s a good observer,” said Furniss. “She now has a greater understanding of what’s involved in developing and growing industry in New York State.”