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Tour

X Rexnord Gear

Tour Code: TT-02
Day and Time: Bus leaves 7:30 AM, Tuesday, Oct. 16, 2012
Length Including Travel Time: 5 ½ hours

Tour Code: WT-01
Day and Time: Bus leaves 7:30 AM, Wednesday, Oct. 17, 2012
Length Including Travel Time: 5 ½ hours

Lean in Concurrent Product and Process Demand

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A 100-year-old business learns new lean tricks

The Canal campus (Rexnord Gear) is 55 acres in downtown Milwaukee, with almost a million square feet of manufacturing space. It is a 100-year-old business that has the largest captive steel foundry in the western hemisphere on site, 70 tons a pour. On this tour you will see 1) the unique manufacturing capability to create gears up to 45 feet in diameter, 2) the breakthrough NPD process that created the V-Class product line for the Falk Brand of gear boxes and 3) Model Plant, the new manufacturing area that is the concurrent process development along with the product development of V-Class. The lean process and tools are a great example in a very high mix low volume environment.

X Rexnord Gear

Rexnord Gear is one of only three plants in the world producing large, precision industry gears up to 45 feet in diameter. The Enclosed Drives business, also on the campus, manufactures and assembles speed reducers for applications in mining, construction, the energy industry and other industrial applications.

Rick Rosser

Rick Rosser is vice president of operations at Rexnord Gear, and was previously the global director of operations for the Rexnord FlatTop division. Prior to working at Rexnord, Rick was with Harley-Davidson for eight years, where he had multiple roles with increasing responsibility across three different plants. Rick spent seven years in the U.S. Army, finishing as a combat engineer company commander before joining Harley-Davidson.



  • No competitors allowed
  • No cameras or other recording devices
  • Safety glasses must be worn
  • Leather-like closed toe shoes must be worn
  • Hearing protection must be worn


Please come to the Tours Registration Desk on the 4th Floor to sign up


Intermediate