POST

A 400HP WEG motor on the hydraulic power unit of a plant’s main mixer failed due to a catastrophic drive-end (DE) bearing issue. The bearing failure generated sparks and halted the production of raw rubber critical for automotive products. With the backup mixer already out of service—its old DC motor awaiting replacement in February 2025—production came to a complete standstill. Upon inspection, it was clear the inner race of the failed bearing had welded itself to the motor shaft. The motor was promptly sent to Horner Machining Services (HMS) division for shaft repair. Once disassembled at Washington Street, HMS discovered deep cracks in the shaft during their inspection—an issue that, if left unaddressed, could lead to premature failure. Over the course of a week, HMS machined off the welded bearing race, repaired the cracks, and returned the shaft for reassembly. By the following Monday, the motor was reassembled, tested, and prepped for customer pickup. By Wednesday afternoon, it was back on-site, reinstalled, and operational. The plant resumed production the next morning. The entire repair process was completed in less than seven days—far surpassing the manufacturer’s quoted lead time of 50-55 days for a new motor. While the customer incurred additional costs for raw materials during the downtime, the expedited repair significantly reduced these expenses, minimizing the financial impact. Horner’s swift action and technical expertise ensured the plant could quickly return to producing high-quality products for the automotive industry, highlighting our commitment to keeping our customers up and running.