Avers Machine & Gear has grown steadily since opening its 30,000‑square‑foot facility in Schiller Park, Illinois, in 1989.
When the company acquired Innovative Rack & Gear – a 20,000‑square‑foot shop in nearby Wood Dale – the leadership team faced a tough integration job.
Two sites, two cultures, and two software stacks needed to become one productive operation.
1. The Challenges Avers Faced
1.1. Two Shops, Two Systems
Different machines and workflows made it hard to move work between locations, leading to bottlenecks and uneven capacity.
1.2. Uneven Programming Standards
Programmers in each facility used their own CAD/CAM solutions, so code was not always transferable.
1.3. Losing Money on a Key Part
One rack was running so slowly it threatened profitability, producing just 12 parts per hour.
2. Why Avers Chose Mastercam
Avers partnered with ShopWare Inc., its local Mastercam representative, to standardise on one CAM platform. Three factors drove the decision:
- Powerful Toolpaths – Dynamic Motion strategies like 2D Dynamic Contour improved chip load and surface finish.
- Flexible Machine Support – Mastercam Mill, Mill 3D, Multiaxis and Lathe covered everything from Doosan mills to Okuma lathes.
- Ongoing Maintenance – The Maintenance Program keeps software current and gives employees access to a support helpline.
3. How Mastercam Improved Daily Work
3.1. One Fixture, Eight Parts
Engineers designed a new rack fixture in SOLIDWORKS, then imported it into Mastercam. The fixture holds eight blanks, eliminating manual flips and turning downtime into cutting time.
3.2. Cycle Time Cut by Two‑Thirds
With the fixture and a single end mill, throughput jumped from 12 racks per hour to 40‑45 racks per hour.
3.3. Flexible Scheduling
Standardised toolpaths let programmers shift repeat jobs between Doosan and Okuma machines to match customer demand.
3.4. Visual Confidence
Mastercam’s simulation tools show full machine kinematics, catching collisions before they happen and giving machinists confidence on first runs.
3.5. Ready for Complex Gears
Upgrading to five‑axis machining broadens the company’s ability to cut intricate geometries like staggered herringbone teeth.
4. The Results: Leaner, Faster Production
| Benefit | Impact at Avers |
| Rack output | Increased from 12 to 40‑45 parts per hour |
| Workflow balance | Jobs shift smoothly between two facilities |
| Programming consistency | 14 programmers share one standard toolkit |
| Future readiness | Maintenance Plan keeps software and skills current |
“Mastercam gives us tremendous flexibility to run repeat jobs in a multitude of work centers. I think the key to any job shop is to be flexible.” – Chris Wellman, President.
5. The Bottom Line
By standardising on Mastercam, Avers Machine & Gear unified two shops, tripled rack throughput and positioned itself for future five‑axis growth.
This content is adapted from the original customer story on Mastercam’s website.
