Industry: Heavy Manufacturing / Industrial Engineering
Component: Triple Reduction Mill Gearbox
Challenge: Bearing Failure + No OEM Support
When a critical triple reduction mill gearbox suffered a severe bearing failure due to a failed lubrication system, the client faced a significant operational risk. To make matters worse, there was no OEM support or technical drawings available for the unit—leaving most repair providers unable to proceed.
That’s where HAYLEY 24/7 DEXIS stepped in.
THE CHALLENGE
The gearbox was a bespoke and aged unit, running in a production-critical role. Without accurate documentation, off-the-shelf parts, or OEM data, the chances of a direct replacement or standard repair were virtually non-existent. The failure posed a serious risk of extended downtime and financial loss for the client.
THE SOLUTION
HAYLEY 247 DEXIS engineering team got to work immediately, reverse-engineering the gearbox from the ground up. Every component was measured, modelled and meticulously remanufactured to restore full function and durability.
The overhaul included:
- A brand-new cassette, shaft, and spiral bevel gearset
- A dynamically balanced vee pulley for smooth operation
- Full strip-down, inspection, rebuild and final performance testing
Every step was completed in-house, allowing for tight control over quality, turnaround, and precision.
THE RESULT
The gearbox was rebuilt to exacting standards and returned to service – without OEM data, and on a fast timeline. The client avoided extended downtime, gained a fully restored gearbox, and now has access to full CAD records and specifications for future servicing. This project highlights the value of HAYLEY 247 DEXIS’ reverse engineering capability, precision machining and commitment to solving complex mechanical problems when others can’t.
