The story is a familiar one in the modern industrial world. In an effort to remain competitive, a business or product moves south to Mexico. Yet while the tide usually flows out, occasionally it comes back in, as Cummins Bridgeway LLC demonstrated recently.
The New Hudson, Mich.-based Cummins distributor, the authorized distributor for Cummins covering Michigan, Ohio and Western Pennsylvania, recently won a bid to relocate the assembly of industrial gaseous-fueled gen-sets from Cummins' San Luis Potosi, Mexico, operations to New Hudson. The gen-sets assembled by Cummins Bridgeway will be sold through the Cummins distribution network.
"We see it as a reverse in the trend that many are concerned about in business these days" said Greg Boll, president and CEO of Cummins Bridgeway. "We're excited to be creating jobs for Michigan workers and manufacturing a globally marketed product."
The gen-sets to be assembled at Cummins Bridgeway are 4.5 and 5.5 kW units that can operate on natural gas or LP. Marketed under the DCathlon brand, they are targeted toward a range of smaller standby power applications, primarily telecommunications, along with railway, personnel lift Both the 4.5 and 5.5 kW units are powered by air-cooled, twin-cylinder Briggs & Stratton OHV gaseous-fueled engines with displacements of 480 cc (4.5 kW) and 570 cc (5.5 kW). The engines are rated 16 and 18 hp, respectively and engine features include cast-iron cylinder liners, alloy exhaust valves, Magnetron electronic ignition systems, electronic engine governors, 12 V electric starters, dual-element air cleaners and integral exhaust systems. They incorporate vapor carburetion systems and operate at speeds from 2200 to 3750 rpm.
The engines directly drive brushless, permanent rare earth magnet alternators that provide 24 and 48 Vdc power. Cummins Bridgeway assembles the rotors and has them machined to fight tolerances. The generator section is air coded through a fan mounted on the rotor.
This configuration provides variable speed operation and allows the generator to "walk into the load" rather than slamming a battery bank, the company said.
Engine and generator operations are monitored through a microprocessor control system that includes a three-position (run-off-auto) switch, a runtime meter and circuit breaker disconnect switch. The system also monitors a series of alarm conditions, including overspeed, overvoltage, undervoltage, overcrank, engine stop, circuit breaker trip and over temperature. It provides status and alarm reporting for remote locations, and an annunciator panel that includes visual alarms is also available as an option.
The engine, generator and controls are mounted in a 16-gauge, powder-coated aluminum sound-attenuated enclosure that helps reduce operating noise emissions to less than 70 dB(A) at 23 ft. The enclosure incorporates an internal starting battery tray and tie down, along with a lockable access door, and the entire enclosure tilts for even greater access, the company said.
The 4.5 kW unit is 41 in. long, 28 in. wide and 31 in. high, with a dry weight of 350 lb. The 5.5 kW gen-set is 41 in. long, 32 in. wide and 37 in. high and weighs 450 lb.
As a result of the new assembly business, Cummins Bridgeway has added an assembly line and created 15 new jobs.
"The business had existing domestic and Canadian customers," said Boll.
"We intend to nurture these and capture new accounts, resulting in sales and employment growth. Potential sales of these products are worldwide in scope."
The primary customer for the gen-sets is Bell South, and Cummins Bridgeway has received its first new order from Rogers Communications, Vancouver, British Columbia.
Cummins Bridgeway employs 600 people, 310 of which are Michigan based. The company sells, distributes and supports Cummins diesel and natural gas engines, gen-sets and related products for automotive, industrial and stationary power applications. It also maintains wholesale parts operations, 14 service locations and a comprehensive training organization. Cummins Bridgeway's sales for 2004 were approximately $230 million
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